Closure system testing apparatus

ABSTRACT

A vehicle closure testing apparatus for opening or closing a vehicle door of any of a variety of vehicles under test includes a supporting structure, a door moving mechanism, and an assembly selectably configured to position the door moving structure. The supporting structure positions the vehicle closure testing apparatus in spaced relationship to the vehicle under test. The door moving mechanism engages and rotates the vehicle door when the door moving mechanism is activated. The assembly enables the door moving mechanism to be movably positioned into a functional position relative to a specific door of the variety of vehicle doors having a specific axis of rotation and enables the door moving mechanism to be re-positioned in a similar functional position relative to a different vehicle door having a different axis of rotation.

This application claims priority from provisional application no.60/002,999 filed on Aug. 9, 1995.

BACKGROUND OF THE INVENTION

1. Scope of the Invention

The closure system testing apparatus described herein provides fullvehicle testing of all body hardware closures. As explained in moredetail below, the full vehicle test system according to the presentinvention simultaneously operates all handles and body closures in amanner that simulates human use of those handles and closures. In thatregard, the system according to the present invention assures that noextraneous loads or added mass are imparted or added to the closures andhandles.

The closure system testing apparatus can be configured to open and closethe doors of any of a variety of vehicles thereby eliminating the needto customize a system for any particular vehicle. The apparatusincorporates modular and adjustable fixturing of various handle andclosure actuators and cyclers attachable to various main and baseframes. The ability to configure the apparatus, in turn, affords thesystem the ability to accommodate a wide range of vehicle sizes fromcompact vehicles to full size vans including pick-up trucks, avoidingthe need to customize the apparatus to work with a particular vehicle.

2. Prior Art

It has been known to provide a vehicle closure testing apparatus foropening and closing particular vehicle doors having a particular axis ofrotation of a particular vehicle under test having a supportingstructure providing support for the vehicle closure testing apparatus.These known supporting structures have been configured to be positionedeither on the outside of the vehicle under test or within the interiorof the vehicle under test. The known outside supporting structures havealso been configured to allow a particular, fully-operational vehicleunder test to be driven onto the outside supporting structure and tosupport the particular, fully-operational vehicle under test includingthe vehicle's wheels and suspension. The outside and inside supportingstructures are positioned relative to the particular vehicle under testsuch that the supporting structure is in a spaced relationship to eitherthe exterior surface or the interior surface of the particular vehicledoor, respectively.

Such known closure systems testing apparatuses also include a doormoving mechanism disposed on the supporting structure that engages thevehicle door and rotates the vehicle door in an opening direction or aclosing direction when the door moving mechanism is activated. It hasbeen known to use an outside door moving mechanism to both open andclose the particular vehicle door, an inside door moving mechanism toboth open and close the particular vehicle door, and both inside andoutside door moving mechanisms to open and close the particular vehicledoor.

These known door moving mechanisms are movably disposed on thesupporting structure at a position that enables the door movingmechanisms to engage an area of contact on the particular vehicle doorand are designed to move in a first direction and a second directioncounter to the first direction. The door moving mechanisms engage thearea of contact on the particular vehicle door and move the door ineither (or both) the opening direction and the closing direction suchthat the area of contact remains fixed while the door moving mechanismopen and close the door.

The known vehicle closure testing apparatuses also include electricactuators operatively associated with the door moving mechanisms andcause the door moving mechanisms to engage and move the particularvehicle door in either (or both) the opening direction or the closingdirection. The electric actuators are controlled by an electric actuatorcontroller communicating with the electric actuators so as to transfercontrol signals to the electric actuators and to receive feedbacksignals indicative of door movements. The electric actuator controllercan control the electric actuators to obtain a desired velocity profilein the movement of the particular vehicle door.

BRIEF SUMMARY OF THE INVENTION

As most will recognize, vehicles come in many sizes and configurations,including sub-compact through full-size vehicles, vans and pick-uptrucks. Each particular door of the many of variety of vehicles has aparticular axis of rotation about which the particular door rotates. Thedegree of inclination and position of an axis of rotation of oneparticular vehicle door is typically quite different from theinclination and position of another vehicle door. Thus, to test anyparticular door, a door moving mechanism must be designed and customizedto move the particular door about the particular door axis. Yet with thevariety of door configurations and the corresponding need to customize atest system for each particular door, it becomes expensive to be able totest all of the variety of vehicles.

Unfortunately, prior art vehicle closure testing apparatuses fail toaddress this limitation. Each prior art testing apparatus was customizedto move a particular vehicle door. Each time a different door needed tobe tested, a new testing apparatus had to be designed and customized towork with the different door.

It is an object of the present invention to overcome the limitations ofthe prior art closure system testing apparatuses. In accordance withthis object, a vehicle closure system testing apparatus capable of beingselectably configured to move any of a variety of vehicle doors from aposition outside of a vehicle under test and being capable of beingre-configured to test a different vehicle door having a different axisof rotation is provided. In that regard, the present invention is avehicle closure testing apparatus for opening and closing a vehicle doorof a vehicle under test wherein the vehicle door has an exterior surfaceand an axis of rotation. The apparatus comprises a supporting structurepositioned outside of the vehicle under test such that the supportingstructure is in a spaced relationship to the exterior surface of thevehicle door and is disposed in an operative position relative to thevehicle under test during a testing of the vehicle door.

The apparatus also includes a door moving mechanism movably disposed onthe supporting structure at a position on the supporting structure thatenables the door moving mechanism to engage the exterior surface of thevehicle door having the axis of rotation when the supporting structureis in the operative position. The door moving mechanism is designed tomove in a first direction and in a second direction counter to the firstdirection such that the door moving mechanism can engage the exteriorsurface of the vehicle door and move the vehicle door in an opening andclosing direction.

The apparatus also includes an assembly disposed on the supportingstructure capable of being selectably configured to position the doormoving mechanism in functional positions relative to exterior surfacesof a variety of vehicle doors having different axes of rotation so thatthe door moving mechanism can engage and move any of the variety ofvehicle doors. The door moving mechanism is movably mounted on theassembly.

The assembly is configured to enable the door moving mechanism to bemovably positioned into a functional position relative to a specificexterior surface of a specific vehicle door having a specific axis ofrotation such that when the specific vehicle door is under test, thedoor moving mechanism pivots about either an axis parallel to thespecific vehicle door axis or an axis aligned and coextensive with thespecific vehicle door axis. The assembly also can be selectablyre-configured to re-position the door moving mechanism in a similarfunctional position relative to a different exterior surface of adifferent vehicle door having a different axis of rotation such thatwhen the different vehicle door is under test, the door moving mechanismpivots about either an axis parallel to the different vehicle door axisor an axis aligned and coextensive with the different vehicle door axis.

It is another object of this invention to provide a vehicle closuresystem testing apparatus capable of being selectably configured to moveany of a variety of vehicle doors from a position inside of a vehicleunder test and being capable of being re-configured to test a differentvehicle door having a different axis of rotation. In that regard, thepresent invention is a vehicle closure testing apparatus for opening andclosing a vehicle door of a vehicle under test wherein the vehicle doorhas an interior surface and an axis of rotation. The apparatus includesa supporting structure positioned inside of the vehicle under test suchthat the supporting structure is in a spaced relationship to theinterior surface of the vehicle door and is disposed in an operativeposition relative to the vehicle under test during a testing of thevehicle door.

The apparatus also includes a door moving mechanism movably disposed onthe supporting structure at a position on the supporting structure thatenables the door moving mechanism to engage the interior surface of thevehicle door having the axis of rotation when the supporting structureis in the operative position. The door moving mechanism moves in a firstdirection and in a second direction counter to the first direction suchthat the door moving mechanism can engage the interior surface of thevehicle door and move the vehicle door in an opening direction and aclosing direction.

The apparatus includes an assembly disposed on the supporting structurecapable of being selectably configured to position the door movingmechanism in functional positions relative to interior surfaces of avariety of vehicle doors having different axes of rotation so that thedoor moving mechanism can engage and move any of the variety of vehicledoors. The door moving mechanism is movably mounted on the assembly.

The assembly enables the door moving mechanism to be movably positionedinto a functional position relative to a specific interior surface of aspecific one of the variety of vehicle doors having a specific axis ofrotation such that when the specific vehicle door is under test, thedoor moving mechanism pivots about either an axis parallel to thespecific vehicle door axis or an axis aligned and coextensive with thespecific vehicle door axis. The assembly can be selectably re-configuredto re-position the door moving mechanism in a similar functionalposition relative to a different interior surface of a different vehicledoor having a different axis of rotation such that when the differentvehicle door is under test, the door moving mechanism pivots abouteither an axis parallel to the different vehicle door axis or an axisaligned and coextensive with the different vehicle door axis.

It is also an object of this invention to provide a vehicle closuresystem testing apparatus capable of being selectably configured to moveany of a variety of vehicle doors from positions both outside and insideof a vehicle under test and being capable of being re-configured to testa different vehicle door having a different axis of rotation. In thatregard, the present invention is a vehicle closure testing apparatus foropening and closing a vehicle door of a vehicle under test wherein thevehicle door has an exterior surface, an interior surface and an axis ofrotation. The apparatus includes an outside supporting structurepositioned outside of the vehicle under test such that the outsidesupporting structure is in a spaced relationship to the exterior surfaceof the vehicle door and is disposed in an operative position relative tothe vehicle under test during a testing of the vehicle door.

The apparatus also includes an inside supporting structure positionedinside of the vehicle under test such that the supporting structure isin a spaced relationship to the interior surface of the vehicle door andis disposed in an operative position relative to the vehicle under testduring a testing of the vehicle door.

The apparatus includes an outside door moving mechanism movably disposedon the outside supporting structure at a position on the outsidesupporting structure that enables the outside door moving mechanism toengage the exterior surface of the vehicle door having the axis ofrotation when the supporting structure is in the operative position. Theoutside door moving mechanism moves in a first direction and in a seconddirection counter to the first direction such that the outside doormoving mechanism can engage the exterior surface of the vehicle door andmove the vehicle door in either an opening direction or a closingdirection.

The apparatus includes an inside door moving mechanism movably disposedon the inside supporting structure at a position on the insidesupporting structure that enables the inside door moving mechanism toengage the interior surface of the vehicle door having the axis ofrotation when said the supporting structure is in the operativeposition. The inside door moving mechanism moves in a third directionand in a fourth direction counter to the third direction such that theinside door moving mechanism can engage the interior surface of thevehicle door and move the vehicle door in the other of the openingdirection or the closing direction.

The apparatus includes an outside assembly disposed on the outsidesupporting structure capable of being selectably configured to positionthe outside door moving mechanism in functional positions relative toexterior surfaces of a variety of vehicle doors having different axes ofrotation so that the outside door moving mechanism can engage and moveany of the variety of vehicle doors. The outside door moving mechanismis movably mounted on the outside assembly.

The outside assembly enables the outside door moving mechanism to bemovably positioned into a functional position relative to a specificexterior surface of a specific one of the variety of vehicle doorshaving a specific axis of rotation such that when the specific vehicledoor is under test, the outside door moving mechanism pivots abouteither an axis parallel to the specific vehicle door axis or an axisaligned and coextensive with the specific vehicle door axis. The outsideassembly also can be selectably re-configured to re-position the outsidedoor moving mechanism in a similar functional position relative to adifferent exterior surface of a different vehicle door having adifferent axis of rotation such that when the different vehicle door isunder test, the outside door moving mechanism pivots about either anaxis parallel to the different vehicle door axis or an axis aligned andcoextensive with the different vehicle door axis.

The apparatus includes an inside assembly disposed on the insidesupporting structure capable of being selectably configured to positionthe inside door moving mechanism in functional positions relative tointerior surfaces of a variety of vehicle doors having different axes ofrotation so that the inside door moving mechanism can engage and moveany of the variety of vehicle doors. The inside door moving mechanism ismovably mounted on said inside assembly.

The inside assembly enables the inside door moving mechanism to bemovably positioned into a functional position relative to a specificinterior surface of a specific one of the variety of vehicle doorshaving a specific axis of rotation such that when the specific vehicledoor is under test, the inside door moving mechanism pivots about eitheran axis parallel to the specific vehicle door axis or an axis alignedand coextensive with the specific vehicle door axis.

The inside assembly also can be selectably re-configured to re-positionthe inside door moving mechanism in a similar functional positionrelative to a different interior surface of a different vehicle doorhaving a different axis of rotation such that when the different vehicledoor is under test, the inside door moving mechanism pivots about eitheran axis parallel to the different vehicle door axis or an axis alignedand coextensive with the different vehicle door axis.

These and other objects of the present invention will become moreapparent during the course of the following detailed description andappended claims. The invention may be best understood with reference tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become apparent from the followingdescription when taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a top plan view of a small main frame of the presentinvention;

FIG. 2 is a side elevational view of a small main frame of the presentinvention;

FIG. 3 is a top plan view of a support assembly of the main frame ofFIG. 1;

FIG. 4 is a front elevational view of a forward frame member of themainframe of FIG. 1;

FIG. 5 is a side elevational view a support assembly of the main frameof FIG. 1;

FIG. 6 is a top plan view of the support assembly of FIG. 5;

FIG. 7 is a rear sectional view of a rearward frame member of the mainframe of FIG. 1;

FIG. 8 is a top plan view of a medium main frame of the presentinvention;

FIG. 9 is a side elevational view of the main frame of FIG. 8;

FIG. 10 is a front elevational view of a forward frame member of themain frame of FIG. 8;

FIG. 11 is a top plan view of a large main frame of the presentinvention;

FIG. 12 is a side elevational view of the main frame of FIG. 11;

FIG. 13 is a front view of a forward frame member of the main frame ofFIG. 11;

FIG. 14 is a top plan view of a check load frame of the presentinvention;

FIG. 15 is a top plan view of an inside base frame of the presentinvention;

FIG. 16 is a side elevational view of the inside base frame of FIG. 15;

FIG. 17 is a top plan view of an outside door arm frame of the presentinvention;

FIG. 18 is a side elevational view of the outside door arm frame of FIG.17;

FIG. 19 is a first embodiment of a moving gear of the present invention;

FIG. 20 is a second embodiment of a moving gear of the presentinvention;

FIG. 21 is an outside door actuator having 90 degree rotation inaccordance with the present invention;

FIG. 22 is a top plan view of the outside door actuator of FIG. 21. ofthe present invention;

FIG. 23 is a side elevational view of the outside door arm of FIG. 21showing alignment of an axis of door rotation;

FIG. 24 is a diagrammatic view of an actuator of the outside door arm ofFIG. 21.;

FIG. 25 is a side elevational view of an interface member of the outsidedoor actuator of FIG. 21;

FIG. 26 is a side elevational view of an interface assembly of thepresent invention;

FIG. 27 is a top plane view of the interface assembly of FIG. 26;

FIG. 28 is a bottom plane view of the interface assembly of FIG. 26;

FIG. 29 is a perspective view of an outside door actuator having 180degree rotation in accordance with the present invention;

FIG. 30 is a side elevational view of the outside door arm of FIG. 29;

FIG. 31 is a top plane view of the actuator of the outside door actuatorof FIG. 29;

FIG. 32 is a side elevational view of the outside door actuator of FIG.29;

FIG. 33 is a side elevational view of the outside door actuator of FIG.29;

FIG. 34 is a side elevational view of an interface assembly of the doorarm actuator of FIG. 29;

FIG. 35 is a top plane view of the interface assembly of FIG. 34;

FIG. 36 is a bottom plane view of the interface assembly of FIG. 34;

FIG. 37 is a top plane view of the inside door actuator having 90 degreerotation in accordance with the present invention;

FIG. 38 is a side elevational view of the door actuator of FIG. 37;

FIG. 39 is a diagram showing the proper alignment of the actuator ofFIG. 37;

FIG. 40 is a diagram showing the proper alignment of the actuator ofFIG. 37;

FIG. 41 is a diagram showing the proper alignment of the actuator ofFIG. 37;

FIG. 42 is a diagram showing the proper alignment of the actuator ofFIG. 37;

FIG. 43 is a diagram showing the proper alignment of the actuator ofFIG. 37;

FIG. 44 is a top plan view of an inside door actuator having 120 degreerotation in accordance with the present invention;

FIG. 45 is a rear cylinder mount of the actuator of FIG. 44;

FIG. 46 is a top plan view of an inside door actuator having 180 degreerotation in accordance with the present invention;

FIG. 47 is a perspective view of the actuator of FIG. 46;

FIG. 48 is a closing interface assembly of the actuator of FIG. 46;

FIG. 49 is an assisted hood actuator of the present invention;

FIG. 50 is a C-shaped lift arm of the actuator of FIG. 49;

FIG. 51 is a mount plate of the actuator of FIG. 49;

FIG. 52 is a lift hand of the actuator of FIG. 49;

FIG. 53 is a cylindrical bracket of the actuator of FIG. 49;

FIG. 54 is a free-fall hood actuator of the present invention;

FIG. 55 is a C-shaped lift arm of the actuator of FIG. 54;

FIG. 56 is a cylinder abutment of the actuator of FIG. 54;

FIG. 57 is a stop cylinder mount plate of the actuator of FIG. 54;

FIG. 58 is a decklid release of the present invention;

FIG. 59 is a support arm of the actuator of FIG. 58;

FIG. 60 is a cylinder mount of the actuator of FIG. 58;

FIG. 61 is a front elevational view of the decklid release of FIG. 58;

FIG. 62 is a head assembly of the decklid release of FIG. 58;

FIG. 63 is a side elevational view of the head assembly of FIG. 62;

FIG. 64 is a decklid actuator of the present invention;

FIG. 65 is a C-shaped arm of the actuator of FIG. 64;

FIG. 66 is a shock mount post of the actuator of FIG. 64;

FIG. 67 is a cylinder post of the actuator of FIG. 65;

FIG. 68 is a shock mount of the actuator of FIG. 64;

FIG. 69 is a side elevational view of the decklid actuator of FIG. 64;

FIG. 70 is a front elevational view of the decklid actuator of FIG. 64;

FIG. 71 is a front elevational view of a outside handle actuator of thepresent invention;

FIG. 72 is a cylindrical bracket of the actuator of FIG. 71;

FIG. 73 is a cylindrical bracket of the actuator of FIG. 71;

FIG. 74 is a C-shaped bracket of the actuator of FIG. 71;

FIG. 75 is a side elevational view of the actuator of FIG. 71;

FIG. 76 is a top plane view of a check load actuator of the presentinvention;

FIG. 77 is a side elevational view of the check load actuator of FIG.76;

FIG. 78 is a lateral air cylinder mount of the actuator of FIG. 76;

FIG. 79 is a clamping block of the actuator of FIG. 76;

FIG. 80 is a mount of the actuator of FIG. 76;

FIG. 81 is a door cycle test system block diagram of the presentinvention;

FIG. 82 is a graphical display of the present invention;

FIG. 83 is a graphical display of the present invention;

FIG. 84 is a door cycle program flowchart of the present invention;

FIG. 85 is a door cycle program flowchart of the present invention;

FIG. 86 is a window cycle flowchart of the present invention;

FIG. 87 is a lock cycle flowchart of the present invention;

FIG. 88 is a outside door handle flowchart of the present invention; and

FIG. 89 is an inside door handle flowchart of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The foundation of the closure system testing (CST) apparatus is thesystem frame. As described below, the CST apparatus includes a mainframe adapted to support a fully-operational vehicle under test. Inother words, the frame is designed to allow a vehicle under test--fullyequipped including suspension--to be driven onto the frame for closuretesting. Once the vehicle under test is secured to the frame, the CSTapparatus can simulate human closure of vehicle doors even though thedoors may be subject to movement because they rest on the vehiclesuspension.

More particularly, the CST apparatus incorporates preferably three mainframes, small, medium, and large, providing the structure upon which theactuation modules are attached. The three discrete frame sizes providethe ability to position the actuation modules substantially near thebody closures for all sized vehicles. In the broadest concept of theinvention, however, only a single frame need be provided.

Moreover, The CST frame including a vehicle under test secured theretois portable. The frame includes moving gears that lift the frame andvehicle under test on rollers thereby allowing the frame, modules andvehicle under test to be transported to different test locations. Thisfeature of the frame allows the vehicle under test to be moved, forexample, to a temperature chamber for cycling of closures at temperatureextremes without having to move the vehicle under test to a second testframe and reconfiguring the modules.

The system according to the present invention also includes actuatormodules controlled in a manner that simulates human use of vehicleclosures without loading the closures with extraneous mass or force. Thevarious actuation modules are adapted to be selectively attached at anythree dimensional position relative to the vehicle under test on any ofthe frames. In that regard, therefore, the closure system test apparatuscan accommodate any vehicle type irrespective of any particular locationof handles and body closures.

The primary actuator modules are those modules that cycle vehicle doors.The term "door" is broader than just those closures that provide accessto a vehicle cab. The door modules can be classified as verticallyhinged door actuators, including for example, rear and side van door andautomobile door actuators, and as horizontally hinged door actuators,including for example, hood and trunk actuators. Additionally, variousdoor actuators are configured for cycling doors from an inside vehicleposition, while others are configured for cycling doors from an outsidevehicle position. The CST apparatus according to the present inventionincludes, as described in more detail below, the following dooractuation modules:

VERTICALLY HINGED DOOR ACTUATORS:

outside door actuator--90 degree rotation;

outside door actuator--180 degree actuation;

inside door actuator--90 degree rotation;

inside door actuator--120 degree rotation;

inside door actuator--180 degree rotation;

HORIZONTALLY HINGED DOOR ACTUATORS:

assisted hood actuator;

free-fall hood actuator;

decklid release; and

decklid actuator.

All of the above-referenced modules are driven by linear or rotaryactuators including, for example, electric and air cylinders andelectric motors. The applicants have learned, however, that electriccylinders and motors are preferred over other actuators when moreprecise control over velocity profiles of door closures is required tosimulate human closure of vehicle doors. For example, one testrequirement may be to initially close a car door slowly then acceleratethe door to slam it closed. To simulate such a velocity profile,electric actuators are preferred. Additionally, electric actuators arebetter suited for achieving repeatable test results at temperatureextremes. Outputs of hydraulic and pneumatic cylinders vary as thetemperature of the hydraulic oil and air varies.

The CST apparatus also includes various handle and check load modulesthat cooperate with the door modules to complete a door cycle. Forexample, an outside door handle actuator would release a door latch bypulling an outside door handle prior to the outside door actuatorcycling the door. Once the door actuator opened the door, a check loadmodule would load the door checks. The following modules arerepresentative of the modules that could be incorporated into the CSTapparatus:

check load actuator; and

outside handle actuator.

Preferably, each of the actuation modules that must drive body closuresthrough varied expected loads, small sedan compact vehicle doors versusfull size coupe doors, for example, is provided in at least two forceoutput sizes. Of course, in the broadest concept of the invention, theactuation modules need only be sized for the largest expected load.Thus, as one skilled in the art will recognize readily, the modularnature of the closure system testing apparatus provides numerousconfigurations that can be adapted to the design of any particularvehicle or to the requirements of the user of the presently contemplatedinvention. In its simplest embodiment, the closure system testingapparatus of the present invention includes one of the frames and one ofthe actuation modules attached thereto. Different and/or additionalactuation modules can be attached to the frame to meet specificrequirements.

The description of the CST apparatus that follows begins with adisclosure of the individual modules including their structure,operation and relationship to both the frame and vehicle under test.Thereafter, the overall system concept is presented.

FRAMES

MAIN FRAMES

The closure system test apparatus includes three main frames thatsupport both the vehicle under test and the actuation modules. The mainframes are sized to accommodate various sized vehicles and are embodiedpreferably in three sizes: small, medium, and large. The main framessubstantially encircle the exterior of the vehicle under test therebyproviding the foundation upon which exterior actuation modules areattached. An interior base frame is also provided. The interior baseframe is disposed fixedly to the interior of the vehicle under test andprovides the foundation upon which interior actuation modules areattached. Finally, a check load frame is provided. The check load frame,as described in more detail below, is disposed horizontally on a mainframe and provides the foundation upon which check load fixtures areattached.

As shown in FIGS. 1 and 2, the small main frame is designated generallyby the reference number 100. The small main frame includes a forwardframe member 102 and a rearward frame member 104 laterally spacedtherefrom such that the longitudinal separation between the framemembers is at least longer than the longitudinal wheelbase of a compactsedan. As configured, the forward frame member 102 can be positionedrelatively forward of a forward edge of a front door of a compact sedanunder test while the rearward frame member 104 is positioned rearward ofa rear edge of a rear door of the vehicle under test. Preferably, theseparation between the forward and rearward frame members issufficiently wide so that an exterior side fuel door of a vehicle undertest positioned on the small main frame would be between the forward andrearward frame members. Two, substantially parallel longitudinal framemembers 106 are disposed on the top exterior positions of the forward102 and rearward 104 frame members extending therebetween thus spanningthe separation and connecting the forward frame member 102 to therearward frame member 104. Two, substantially parallel vehicle supports108, having a pair of holes 110 laterally spaced at each end providingattachment points, are disposed on a bottom interior position of theframe members extending therebetween. The vehicle supports 108 providethe bearing surface 112 upon which the vehicle under test rests and are,thus, laterally spaced at a distance substantially equal to a transversewheelbase of a compact vehicle. Preferably, the vehicle supports 108 areconstructed from "C" channel, oriented in an upwardly facing or "U"configuration, sufficiently wide to accommodate a range of compactvehicles with varied wheelbases. Preferably as well, the vehiclesupports 108 extend farther than the separation between the forward andrearward frames 102, 104 thereby maximizing the ability to position thevehicle under test relative to the main frame. Finally, the small mainframe includes at least one transverse member 114 disposed substantiallyperpendicularly between the parallel, longitudinal frame members 106.Preferably, the small main frame includes three transverse members 114.

More particularly, as best viewed in FIG. 4, the forward frame member102 comprises two, substantially parallel transverse members,conveniently labeled the upper 116 and lower 118 transverse members,vertically spaced at a distance higher than the expected height of acompact vehicle. Two substantially parallel vertical members, left 120and right 122 vertical members, are provided. Each of the verticalmembers are disposed in abutting relationship to opposing ends of eachof the transverse members, preferably attached by welding, such that thetransverse members 116, 118 and the vertical members 120, 122 provide arectangular configuration as viewed in the longitudinal direction. Thewidth of the transverse members, of course, is wider than the expectedwidth of the vehicle under test. As viewed from the longitudinaldirection, a stiffener member 124 is disposed in each of the upper,inside corners of the rectangular configuration attached, preferably bywelding, between the vertical members 120, 122 and the transversemembers 116, 118, preferably at 45 degrees. The rectangularconfiguration comprising the vertical members 120, 122 and thetransverse members 116, 118 is attached, again preferably by welding, tosupport assemblies 126. The support assemblies comprise a T-shapedmember attached to the lower, outside corners of the rectangularconfiguration such that the vertical segment 127 of the "T" abuts abottom surface of the lower transverse member 118. The horizontalsegment 129 of the "T" extends perpendicularly to the plane formed bythe rectangular configuration. As best viewed in FIG. 2, a secondstiffener member 128 is disposed between each of the vertical members120, 122 and the horizontal segment 129 of its associated T-shapedmember, preferably at 45 degrees. Placement of the second stiffenermembers 128 forward or aft of the vertical members 120, 122 is merely amatter of design choice. As best viewed in FIG. 3, a third stiffenermember 130 is disposed between each of the horizontal segments 129 ofthe T-shaped members and the vertical segments 127 of the T-shapedmembers, preferably at 45 degrees. Placement of the third stiffenermembers 130 forward or aft of the lower transverse member 118 is merelya matter of design choice; however, the second 128 and third 130stiffener members should be disposed preferably on opposed sides of therectangular configuration of the forward frame member 102.

As best viewed in FIG. 3, a pair of flanges 132 are disposed on theforward facing surface of the lower transverse member 118 such thathorizontal surfaces of the flanges are substantially within the planedefined by the upper surface of the lower transverse member 118. Theflanges 132 are spaced laterally from a mid point of the lowertransverse member 118 at a distance corresponding roughly to thewheelbase of the vehicle under test. Preferably, a linear slot 134extending in the transverse direction is disposed through each of theflanges 132 thereby providing a convenient place to which the vehiclesupports 108 can be attached to the flanges 132 by mechanical fasteners.The linear slots 134 provide the ability to attach the vehicle supports108 by mechanical fasteners passing through the holes 110 in thesupports in various lateral positions to thereby accommodate vehicles ofvarious wheelbases. In the alternative, the linear slots 134 may bereplaced with a linear array of holes.

As shown in FIG. 5, a height adjuster 136 is provided. The heightadjuster 136 comprises a length of rectangular steel tube having a pairof through holes extending through both opposed walls of thetube--spaced identically with the holes of the supports 108--that can bealigned with the linear slots 134 of the vehicle supports 108. A heightadjuster 136 is disposed, as required, between each flange 132 and itsassociated vehicle support 108 thereby providing a convenient method ofadjusting the relative height of the vehicle under test.

As best seen in FIGS. 1 and 2, a tubular track assembly 138 is disposedon the underside of the vehicle supports 108. The track assemblycomprises a pair of L-shaped flanges 140 fixed, preferably by welding,to the underside of each vehicle support 108. A steel tubular member 142is fixed, preferably by welding, between each of the flanges 140 andextends substantially parallel with the vehicle supports 108.Preferably, intermediate brackets 144 fixed between intermediatepositions of the tubular member and the vehicle supports are provided.

Finally, pairs of chocks 146 are provided for each vehicle support forsecuring the vehicle under test from longitudinal movement duringtesting. Each chock comprises a pair of plates 148 wider than the widthof the vehicle support 108 having holes at each end. The chocks aresecured to the vehicle supports by mechanical fasteners passing throughthe holes.

Disposed on the rearward facing surface of each of the vertical members120, 122 substantially within the plane of the lower surface of theupper transverse member 114, a plate 150 extends rearwardly from each ofthe vertical members 120, 122 providing a support for the longitudinalmembers 106. A fourth stiffener member 152 is disposed between each ofthe plates 150 and the vertical members 120, 122, preferably at 45degrees. A plurality of holes extend through the plates 150 therebyproviding a location for attachment of the longitudinal members 106 tothe forward frame member 102 by mechanical fasteners.

As shown in FIGS. 6 and 7, the rearward frame member 104 comprises two,substantially parallel vertical members, conveniently labeled the right154 and left 156 vertical members, laterally spaced at a distancegreater than the expected width of a compact vehicle. A transversemember 158 is provided. The transverse member 158 is disposed inabutting relationship to lower ends of each of the vertical members 154,156, preferably attached by welding, such that the transverse member 158and the vertical members 154, 156 provide an upright U-configuration asviewed in the longitudinal direction. The upright U-configurationcomprising the vertical members 154, 156 and the transverse member 158is attached, again preferably by welding, to support assemblies 160. Thesupport assemblies 160 comprise a T-shaped member attached to the lower,outside corners of the U-configuration such that the vertical segment161 of the "T" abuts a bottom surface of the lower transverse member158. The horizontal segment 163 of the "T" extends perpendicularly tothe plane formed by the U-configuration. As best viewed in FIG. 2, astiffener member 162 is disposed between each of the vertical members154, 156 and the horizontal segment 163 of its associated T-shapedmember, preferably at 45 degrees. Placement of the stiffener members 162forward or aft of the vertical members 154, 156 is merely a matter ofdesign choice. A second stiffener member 164 is disposed between each ofthe horizontal segments 163 of the T-shaped members and the verticalsegments 161 of the T-shaped members, preferably at 45 degrees.Placement of the second stiffener members 164 forward or aft of thelower transverse member 158 is merely a matter of design choice;however, the first 162 and second 164 stiffener members should bedisposed preferably on opposed sides of the U-configuration of therearward frame member 104.

As best viewed in FIG. 6, a pair of flanges 166 are disposed on therearward facing surface of the lower transverse member 158 such thathorizontal surfaces of the flanges are substantially within the planedefined by the upper surface of the lower transverse member. Asassembled, the upper surfaces of the lower transverse members 118, 158of the forward and rearward frame members, respectively, and thehorizontal surfaces of the forward 132 and rearward 166 flanges arecoplanar. The flanges 166 are spaced laterally from a mid point of thelower transverse member 158 at a distance corresponding roughly to thewheelbase of the vehicle under test. Preferably, a linear slot 168extending in the transverse direction is disposed through each of theflanges 166 thereby providing a convenient place to which the vehiclesupports 108 can be attached to the flanges by mechanical fasteners. Thelinear slots 168 provide the ability to attach the vehicle supports 108in various lateral positions affording the capability to accommodatevehicles of various wheelbases. Alternatively, the slots 168 can bereplaced by a linear array of holes.

Disposed on the forward facing surface of each of the vertical members154, 156 substantially within the plane of the lower surface of theupper transverse member 116 of the forward frame member 102, a plate 170extends forwardly from each of the vertical members providing a supportfor the longitudinal members 106. A third stiffener member 172 isdisposed between each of the plates 170 and the vertical members 154,156, preferably at 45 degrees. A plurality of holes extend through theplates 170 thereby providing a location for attachment of thelongitudinal members 106 to the rearward frame member 104 by mechanicalfasteners.

The longitudinal members 106 comprise a plate 174 attached to the topsurface of the longitudinal members 106, preferably by welding, to eachof the opposing ends of the longitudinal members 106 and extendsubstantially parallel with the top surface of the longitudinal members106 past the opposing ends. The plate is also wider than the surface towhich it is attached and defines a plurality of holes on each side ofthe plate 174 along the portion of the plate extending over the width ofthe longitudinal member 106. The plurality of holes in the plates of thelongitudinal members align with the holes of the longitudinallyextending plates 150, 170 of the forward 102 and rearward 104 frames.Mechanical fasteners join the longitudinal members 106 to the forward102 and rearward 104 frames. The longitudinal members 106 furthercomprise a second plate 176 disposed perpendicularly and downwardly onthe extended ends of the first plates 174. The second or perpendicularplate 176 is also wider than the width of the longitudinal member 106.The perpendicular plates define a plurality of holes along the lateraledges. A final, unattached plate 178 having a plurality of holes thatare alignable with the holes of the perpendicular plates 176 is providedfor each end of the longitudinal members 106.

As configured, the longitudinal members 106 are positioned on theforward and rearward members so that the perpendicular plates 176 abutthe forwardly facing surfaces of the vertical members 120, 122 of theforward frame 102 and the rearwardly facing surfaces of the verticalmembers 154, 156 of the rearward frame 104. The unattached plates 178are positioned between the ends of the longitudinal members 106 and thevertical members 120, 122, 154, 156 such that the holes of theunattached plates align with the holes of the perpendicular plates. Oncepositioned, the first plates 174 fixed to the longitudinal members 106are fastened to the plates 150, 170 extending from the vertical members120, 122, 154, 156, and the perpendicular plates 176 are fastened to theunattached plates 178. This configuration affords the ability todisassemble the frame if required and provides the flexibility to changethe overall length of the main frame should a longer vehicle need to betested.

The transverse members 114, preferably three transverse members, aredisposed substantially perpendicularly between the longitudinal members106. The transverse members include a plate 180 fixed, preferably bywelding, to the top surface of each end of the transverse member suchthat the plate extends substantially parallel with the top surface ofthe transverse member beyond the ends of the transverse members. Theplates 180 are wider than the width of the transverse members 114 anddefine a plurality of holes along the lateral edges of the plates. Thetransverse members 114 are positioned on the longitudinal members 106such that the ends of the transverse members abut perpendicularlyagainst the longitudinal members and the plates 180 of the transversemembers abut along the top surface of the longitudinal members. Theholes of the plate are spaced such that some of the plurality of holesare on each side of the longitudinal members. An unattached plate 182having a plurality of holes alignable with the plurality of holes of thetransverse member plates 180 is disposed below each plate of thetransverse members 114. The aligned plates 180, 182 clamp the transversemembers 114 to the longitudinal members 106 by mechanical fasteners. Asconfigured, the transverse members may be positioned anywhere along thelength of the longitudinal members where it is necessary to support anactuation module.

As shown in FIGS. 8 through 13, medium and large main frames are alsoprovided. The medium and large main frames 300, 500 are constructed andarranged substantially similarly as the small main frame. Commonelements between the frames share the same reference characters exceptfor the first reference digit. Reference characters 1xx, 3xx and 5xxdesignate small, medium, and large, respectively.

The medium main frame includes a forward frame member 302 and a rearwardframe member 304 laterally spaced therefrom such that the longitudinalseparation between the frame members is at least longer than thelongitudinal wheelbase of a full-size car. The width and height of theforward and rearward frame members 302, 304 are sized larger than thewidth and height of a full-size car. Similarly, the large main frameincludes a forward frame member 502 and a rearward frame member 504laterally spaced therefrom such that the longitudinal separation betweenthe frame members is at least longer than the longitudinal wheelbase ofa full-size van. The width and height of the large forward and rearwardframe members 502, 504 are sized larger than the width and height of afull-size van.

The medium and large rearward frame members 304, 504 include additionalelements not found in the small rearward frame member 104. The mediumand large rearward frame members 304, 305 each comprise two,substantially parallel transverse members, conveniently labeled theupper 359, 559 and lower transverse members 358, 558, vertically spacedat a distance higher than the expected height of a full-sized car and afull-sized van, respectively. Two substantially parallel verticalmembers, left vertical members 356, 556 and right vertical members 354,554, are provided. Each of the vertical members are disposed in abuttingrelationship to opposing ends of each of the transverse members,preferably attached by welding, such that the transverse members and thevertical members provide a rectangular configuration as viewed in thelongitudinal direction. The width of the transverse members, of course,is wider than the expected width of the vehicle under test. As viewedfrom the longitudinal direction, a stiffener member 351, 551 is disposedin each of the upper, inside corners of the rectangular configurationattached, preferably by welding, between the vertical member and thetransverse member, preferably at 45 degrees. The rectangularconfiguration comprising the vertical members and the transverse membersis attached, again preferably by welding, to support assemblies, asdescribed above. The additional upper transverse member of the mediumand large rearward frames provides additional stability and rigidity tothe larger frames.

Also as shown in FIGS. 8 and 11, the flanges 332, 532 supporting thevehicle supports are disposed on the rearward facing surfaces of thelower transverse members for both the medium and large forward framemembers.

For all of the main frames, the transverse, longitudinal, and verticalmembers are preferably constructed from rectangular steel tube.

CHECK LOAD FRAME

As shown in FIG. 14, a check load frame 700 providing support for checkload fixtures, described below, is provided. The check load frame 700comprises a longitudinal member 702 constructed preferably fromrectangular steel tube and preferably having a length at least equal tothe vehicle under test. As configured, the longitudinal member 702 islonger than the longitudinal members 106, 306, 506 of the main frames100, 300, 500. A first support member 704 is fixed, preferably bywelding, to the forward end 703 of the longitudinal member 702 andextends perpendicularly therefrom. A second support member 706 laterallyspaced from the opposed end 705 of the longitudinal member 702 is fixed,preferably by welding, thereto and extends perpendicularly therefrom. Aplate 708 is fixed to each opposing end of the support members,preferably by welding. The plates 708 define a plurality of holes aroundthe periphery of the plate. A second plate 710 is provided for each ofthe support members 704, 706. The second plate 710 also defines aplurality of holes positioned identically to the holes in the firstplate thereby providing a mounting bracket. As configured, the firstsupport member 704 abuts one of the vertical members 120, 122, 320, 322,520 or 522 of the forward frame members 102, 302 or 305, respectivelyand is fixed thereto by one of the second plates 710 and mechanicalfasteners. The second support member 706 abuts one of the verticalmembers 154, 156, 354, 356, 554 or 556 of the rearward frame members104, 304, 504, respectively and is fixed thereto by the other secondplate 710 and mechanical fasteners. Conventional mechanical fastenersare used to mount the check load frame to the main frame.

INSIDE BASE FRAMES

The closure system test apparatus also includes an interior base frame900. The interior base frame 900, one embodiment of which is shown inFIGS. 15 and 16, is disposed fixedly to the interior of the vehicleunder test and provides the foundation upon which interior actuationmodules are attached. Generally, the interior base frame 900 includes asupport frame 902, a base plate 904 attached to the support frame 902,and a plurality of flanges 906 also attached to the support frame 902.The plurality of flanges 906 provide the points of attachment,preferably by mechanical fasteners, to fix the interior base frame 900to the interior of the vehicle under test.

More specifically, the support frame includes two transverse members 908disposed on the bottom surface and along the longitudinal edges of thebase plate 904. A plurality of longitudinal members 910, also disposedon the bottom surface of the base plate 904, abut the transverse members908 at each of their opposed ends. Both the transverse members 908 andthe longitudinal members 910 are constructed preferably from rectangularsteel tubing. The transverse members 908 are disposed substantiallyparallel to each other in the transverse direction along the interiorfloor of the test vehicle. The top surface of the transverse members 908each define at least one hole proximate to each end of each transversemember 908. The plurality of longitudinal members 910 are disposedsubstantially parallel to each other, along the longitudinal direction,proximate to the interior floor of the test vehicle such that thesupport frame members 908, 910 form a fixed rectangular frame 902.

Each opposing end of the longitudinal members 910 is attached to a faceof a transverse member 908, preferably by welding. Any interior membersof the plurality of longitudinal members 910 is disposed substantiallyequidistantly from the longitudinal members 910 disposed along the edgesof the base plate 904. The top surfaces of the support frame members908, 910 are all substantially within a single plane such that the frame902 provides a surface to support the base plate 904.

The base plate 904 is sized and shaped to fit within the interior spaceof a vehicle under test. A rectangular configuration has provensuitable. The base plate 904 also defines a first plurality of holes 916and second plurality of holes 918 therein. The first plurality of holes916 in the base plate 904 are proximate to the four corners of the plate904 such that each hole is aligned with one of the four holes defined bythe two transverse members 908. Each of the first plurality of holes 916in the base plate 904 is wider at the top of the hole than at the bottomof the hole in a manner suitable for recessing the head of a mechanicalfastener. The base plate 904 is attached to the support frame 902 bypassing a mechanical fastener through each of the first plurality ofholes 916 in the base plate 904 and the corresponding hole in thetransverse frame member 908 such that the top portion of the mechanicalfastener does not extend above the top surface of the base plate 904.

In the embodiment shown in FIG. 15, the second plurality of holes 918are arranged in rows and columns. One skilled in the art will recognizereadily that there are innumerable configurations for the number andarrangement of the second plurality of holes 918 in the base plate 904.Specifically, the second plurality of holes 918 defined by the baseplate 904, as shown in the embodiment of FIG. 15, comprise 126 holesarranged in 14 columns and 9 rows such that the distances betweenadjacent rows are all substantially equal, the distances betweenadjacent columns are all substantially equal, and the inter-row distanceis substantially equal to the inter-column distance. The secondplurality of holes 918 thus forms a two-dimensional square latticepattern of holes which substantially spans the surface of the base plate904.

As is most easily seen in FIG. 16, the flanges 906 have L-shapedcross-sections. A linear slot 912, which extends in the transversedirection, is disposed through each of the flanges 906. Preferably, afirst and second flange 906 are fixed, preferably by welding, to eachtransverse member 908 such that the bottom surfaces of the flanges 906are substantially within the plane defined by the bottom surface of thetransverse frame members 908, and the flanges 906 extend outwardly fromthe support frame 902. A first flange 906 is fixed to the end of eachtransverse frame member 908 such that one end of the flange issubstantially in the plane defined by the end of the support framemember 908 and the flange 906 extends transversely therefrom. The secondflanges 906 are fixed to the ends of the transverse frame members 908opposed to the first flanges 906, but the second flanges are displacedin the transverse direction such that there are gaps between the end ofthe second flanges 906 and the corresponding end of the transverse framemembers 908.

A third flange 906 is fixed, preferably by welding, to the outer face ofthe first longitudinal frame member 910 which is most proximate to thefirst flanges 906 such that the third flange 906 extends substantiallyperpendicularly therefrom. The bottom surface of the third flange 906 issubstantially in the plane of the bottom surface of the longitudinalsupport member 910. The third flange 906 is preferably substantiallycentered along the longitudinal frame member 910.

The interior base frame 900 is fixed to the interior floor of the testvehicle by passing mechanical fasteners through the linear slots 912 inthe flanges 906 and corresponding holes in the floor of the vehicleunder test. The second plurality of holes in the base plate 904 aresuitable for accommodating a variety of interior test components andinterior actuators. The length and width of the interior base frame aresuitable for the size of the vehicle under test.

TRANSVERSE 180 DEGREE OUTSIDE DOOR ARM FRAME

A transverse 180 degree outside door arm frame 1100 provides a lowersupport for a 180 degree outside door arm actuator, described below. Thetransverse frame 1100 can be positioned rearwardly of the rearward framemember or forwardly of the forward frame member. As shown in FIGS. 17and 18, the transverse frame 1100 comprises a cylindrical steel tube1102 disposed upon two mounts 1104 positioned at each opposed end of thecylindrical tube 1102. More particularly, the mounts 1104 comprise aplate 1106 having two holes 1108 therethrough and a cylindrical bracket1110 fixed, preferably by welding, on the upper edge of the plate. Thecylindrical bracket 1110 includes two mating semi-circular members that,upon assembly, define a bore therethrough. The two semi-circular membersare adapted to be connected to the cylindrical tube by separating thehalves, positioning the halves about the tube, and clamping the halvesto the tube by any suitable means. Specifically, the semi-circularmembers incorporates screws that pass through one semi-circular memberand tighten upon threads tapped into the opposing semi-circular member.The cylindrical brackets 1110 are fixed to the plates 1106 such that thebore of the cylindrical brackets 1110 is oriented perpendicularly to theplate 1106.

The mounts 1104 are fixed by mechanical fasteners passing through theholes 1108 to the outwardly facing, vertical surfaces of the horizontalsegment of the "T"-shaped support assemblies 160, 360 or 560 such thatthe cylindrical brackets 1110 are disposed upwardly and alignedlaterally with each other. The cylindrical tube 1102 is secured to themounts 1104. As described below, the transverse mount 1100 provides thelower bearing mount for the 180 degree outside door arm actuator.

MOVING GEARS

Detachable moving gears 1300 are provided for transporting the mainframes 100, 300, 500 including any attached modules and/or vehiclesunder test. Preferably, the moving gears 1300 are provided in two sizes.A small moving gear is adapted for use with the small main frame, andthe large moving gear is adapted for use with the medium and large mainframes. The size of the moving gears 1300 is dictated by the expectedloads. In general, as shown in the FIG. 19, the moving gears 1300comprise a conventional crank jack 1302 having an extensible piston orscrew 1304. The piston 1304 is extended by the rotation of a crank 1306.In the broadest concept of the moving gears, however, any suitabledevice providing the required lift including, for example, a hydrauliclift, could be substituted. The crank piston or screw 1304 is attachedat its free end to a caster plate 1308. A conventional dual wheel caster1310 is attached to the caster plate 1308. More particularly, the casterplate 1308 defines spaced holes therethrough in a substantiallyrectangular configuration. The holes provide a mounting point for thecaster 1310 through which mechanical fasteners 1312 pass therebyattaching the caster 1310 to the crank jack 1302.

In a first embodiment of the moving gear, as shown in FIG. 19, the crankjack 1302 is mountable to a main frame by an upper mount weldment 1314and a lower mount weldment 1316. The upper mount weldment 1314 comprisesa C-channel member 1318 defining a pair of holes 1320 extending throughboth parallel portions 1322 of the C-channel member 1318. Moreover, theparallel portions 1322 of the C-channel member 1318 are spaced apartwider than the width of the vertical members of the forward and rearwardframes 102, 302, 502, 104, 304, 504. A rectangular steel tube 1324 isfixed to the C-channel member 1318 and extends therefrom in a directionopposed to the parallel portions 1322 of the C-channel member 1318. Amounting plate 1326 is fixed to the rectangular steel tube 1324 anddefines a plurality of holes through which mechanical fasteners 1328attach the upper mount weldment 1314 to the crank jack 1302. Moreparticularly, the crank jack 1302 includes a mounting bracket 1330 fixedthereto to which the upper mount weldment 1314 is attached such that theupper mount weldment 1314 extends substantially perpendicularly from thecrank jack 1302.

Similarly, the moving gear 1300 includes a lower mount weldment 1316comprising a C-channel member 1332 defining a hole 1334 extendingthrough both parallel portions 1336 of the C-channel member 1332.Moreover, the parallel portions 1336 of the C-channel member 1332 arespaced apart wider than the width of the vertical members of the forwardand rearward frames 102, 104, 302, 304, 502, 504. A rectangular steeltube 1338 is fixed to the C-channel member 1332 and extends therefrom ina direction opposed to the parallel portions 1336 of the C-channelmember 1332. A muffler clamp 1340 is fixed at the opposing end of therectangular steel tube 1338. The muffler clamp 1340 clamps the lowermount 1316 to the crank jack 1302. As configured, the upper mount 1314and the lower mount 1316 extend perpendicularly in the same plane fromthe crank jack 1302 such that the parallel portions 1322, 1336 of theC-channel members 1318, 1332, when attached to the main frame, arepositioned about the vertical members of the rearward and forwardframes. This embodiment of the moving gear 1300 is configured to beattached to the forward and rearward frame members in the same plane asthe rectangular configurations of the forward and rearward framemembers. Mechanical fasteners (not shown), suitable for removal, passthrough the holes of the C-channel members 1318, 1332 and fix the movinggear 1300 to the main frame at each lower corner of the main frame.

To move the main frame, the crank jack handle 1306 is rotated therebyraising or lowering the main frame by extension or retraction of thecrank piston 1304. Generally, the crank piston 1304 must extend througha travel sufficient to raise the main frame for transport on the dualcasters 1310. Preferably, the crank jack 1302 should provide at leastthree quarters of an inch of travel.

As shown in FIG. 20, a second embodiment of the moving gear 1350 isdesigned to be attached to the rearward and forward frame membersperpendicular to the rectangular configurations of the forward andrearward frames. In the second embodiment, the moving gear 1350comprises, as in the first embodiment, a crank jack 1352, a caster plate1358 fixed at a free end of an extensible piston or screw 1354, a dualwheel caster 1360 attached to the caster plate 1358, and a moving gearmount weldment 1364.

The moving gear mount weldment 1364 comprises a C-channel member 1366defining a single hole 1368 through both parallel portions 1370 of theC-channel member 1366. The parallel portions 1370 of the C-channelmember 1366 are spaced sufficiently wide to be mountable to the verticalmembers of the rearward and forward frame members. A first rectangularsteel tube 1372 is fixed to the C-channel member 1366 and is positionedgenerally horizontally. The rectangular steel tube 1372 is sufficientlylong to extend the length of the horizontal segment 129, 329, 529 of the"T"-shaped support assembly 160, 360, 560 fixed to the forward andrearward frame members. A second rectangular steel tube member 1374 isfixed perpendicularly, preferably by welding, to the first rectangularsteel tube member 1372 and is spaced laterally from the ends of thefirst rectangular steel tube member 1372. The second rectangular steeltube member 1374 is generally parallel to the crank jack 1352. Amounting bracket 1376, identical to the mounting bracket 1326 of thefirst embodiment, is fixed to the end 1378 of the first rectangularsteel tube member 1372. A third rectangular steel tube member 1380 isfixed to the second rectangular steel tube member 1374, preferably bywelding, and extends perpendicularly therefrom. The first rectangularsteel tube member 1372 and the third rectangular steel tube member 1380are generally parallel and coplanar. A muffler clamp 1382 is fixed tothe opposed end of the third rectangular steel tube member 1380.Finally, a fourth rectangular steel tube member 1384 is fixed to theopposed end of the second rectangular steel tube member 1374. The fourthrectangular steel tube member 1384 extends perpendicularly from thesecond rectangular steel tube member 1374 and is generally parallel andcoplanar with the first rectangular steel tube member 1372. The fourthrectangular steel tube member 1384, however, extends in a directionopposite that of the third rectangular steel tube member 1380. Moreover,the fourth rectangular steel tube member 1384 is dimensionally smallerthan the inside dimensions of the horizontal segment 129, 329, 529 ofthe "T"-shaped support assembly of the main frame. As configured, thefourth rectangular steel tube member 1384 is insertable into thehorizontal segment 129, 329, 529 of the "T"-shaped support assembly ofthe main frame. The weldment 1364 is sized such that when the fourthrectangular steel tube member 1384 is completely inserted into thesupport assembly, the C-channel member 1366 of the first rectangularsteel tube member 1372 is positioned about the vertical arm of therearward or forward frame members. The C-channel member 1366 is securedto the main frame by mechanical fasteners. As with the first embodiment,the crank jack 1352 should provide sufficient travel to lift the mainframe for transport. Preferably, the travel should be approximatelythree quarters of an inch.

DOOR ACTUATION MODULES

VERTICALLY HINGED DOOR ACTUATORS

outside door actuator--90 degree rotation

The outside door, 90 degree actuators 2700 are configured to cycle doorsmounted for rotation about a vertical axis (as compared withhorizontally mounted doors like decklids and tailgates) throughapproximately a 90 degree rotation. The 90 degree outside door actuators2700, generally, comprise an outside door arm 2703, a powered driver2731, support fixtures and brackets, bearings and bearing mounts, andinterface members disposed between the door arm 2703 and the vehicledoor specifically designed for an opening or closing function.

As best viewed in FIG. 21, an outside pivot arm 2703 is provided. Thepivot arm 2703 comprises two horizontal members disposed on opposingends of a vertical member extending therefrom in the same plane at rightangles. The members are attached, preferably by welding, by any suitablemethod. As configured, the outside pivot arm 2703 forms a block C-shape.Preferably, a stiffener member (not shown) is disposed in each of theinside corners of the pivot arm 2703, and the pivot arm 2703 isconstructed from steel tubing.

The pivot arm 2703 is mountable to the main frames by an assembly ofbrackets and bearings. An upper bearing assembly 2705 is selectivelyconnectable to the upper horizontal arm of the pivot arm 2703 and isselectively connectable to the main frame and provides an upper pivotpoint for the pivot arm 2703. Similarly, a lower bearing assembly 2717is selectively connectable to the lower horizontal arm of the pivot arm2703 and is selectively connectable to the main frame and provides alower pivot point for the pivot arm 2703. More particularly, as shown inFIG. 21, the upper bearing assembly 2705 comprises an upper bearingmount 2706 preferably constructed from steel plate having a mountingportion 2707 and a bearing portion 2708. The mounting portion 2707defines a plurality of mounting holes therethrough. The plurality ofholes are spaced laterally at a distance greater than the width of atransverse member of a main frame, as described in more detail below, towhich the bearing assembly 2705 is to be attached. The holes provide apassage through which mechanical fasteners pass that, upon assembly,secure the upper bearing assembly 2705 to a main frame. Preferably, theupper bearing mount 2706 includes four equally spaced holes. The bearingportion 2708 of the mount 2706 extending from the mounting portion 2707provides a surface upon which a bearing 2709 is mounted. Anyconventional bearing adapted for the expected axial loads and cyclefrequency may be incorporated. A clamp pad 2711, dimensionally similarto the mounting portion 2707 of the upper bearing mount 2706, isprovided. The clamp pad 2711 also defines a plurality of holestherethrough spaced identically as the mounting portion 2707 of theupper bearing mount 2706 such that, upon assembly, the holes of bothmembers align.

The upper bearing assembly 2705 also comprises an upper pivot bracket2713. The upper pivot bracket 2713 comprises a pin 2715 having an endsuitably adapted for insertion and attachment to the bearing 2709. Inthe presently preferred embodiment, threads are provided on the bearingend of the pin 2715. The opposing end of the pin 2715 is attached to acylindrical bracket 2714. Specifically, the cylindrical bracket 2714defines a hole through a lateral side of the bracket 2714 into which thepin 2715 is inserted. The pin 2715 is secured to the bracket 2714 bywelding. More particularly, the cylindrical bracket 2714 includes twomating semicircular members that, upon assembly, define a boretherethrough. The two semi-circular members are adapted to be connectedto the upper horizontal arm of the pivot arm 2703 by separating thehalves, positioning the halves about the upper horizontal arm of thepivot arm 2703, and clamping the halves to the pivot arm 2703 by anysuitable means. Specifically, the semi-circular members of the upperpivot bracket 2713 incorporate screws that pass through onesemi-circular member and tighten upon threads tapped into the opposingsemi-circular member. (The cylindrical brackets are used throughout theCST apparatus. Except for the relative size of the various bracketsincorporated into the CST apparatus, the brackets are constructed andarranged similarly. Any reference to cylindrical bracket incorporates byreferences the preceding description.)

The upper bearing assembly 2705 is configured as follows. The upperpivot bracket 2713 is secured to the upper horizontal arm of the pivotarm 2703 such that the pin 2715 extends substantially vertically andupwardly therefrom. The lateral position of the upper pivot bracket 2713along the upper horizontal arm of the pivot arm 2703 is dictated by thesize of the door to be rotated. The pin 2715 is secured to the bearing2709, and thereafter, the upper bearing mount 2706 is mounted to a mainframe, typically though not necessarily to a transverse member forwardof a pivot point of the door under test such that the upper bearingmount 2706 extends rearwardly, by clamping the upper bearing mount 2706and clamp pad 2711 about a member of the main frame.

Similarly, a lower bearing assembly 2717 is provided. The lower bearingassembly 2717 comprises in part a support bracket 2719. As shown in FIG.22, the support bracket 2719 includes a cylindrical bracket 2720 similarto the cylindrical bracket described above. Specifically, thecylindrical bracket 2720 includes two mating, semi-circular membersdefining a bore therethrough when mated. The cylindrical bracket 2720 isadapted to be selectively connectable to the longitudinal memberdisposed below the vehicle support of a main frame. A tubular member2721 is welded or otherwise fixed to the cylindrical member 2720 andextends perpendicularly therefrom. The lower bearing assembly 2717 alsoincludes a lower bearing mount 2722 having a mounting portion 2723 and abearing portion 2724 preferably constructed from steel plate. Themounting portion 2723 comprises a cylindrical bracket as defined aboveadapted for connection to the tubular member 2721 of the support bracket2719. The bearing portion 2724, a steel plate, is fixed to the mountingportion 2723 and extends therefrom such that the bearing portion 2724 ispositioned horizontally and provides a surface upon which a bearing 2725is mounted. Any conventional bearing adapted for the expected axialloads and cycle frequency may be incorporated.

The lower bearing assembly 2717 also comprises a lower pivot bracket2727. The lower pivot bracket 2727 comprises a pin 2729 having an endsuitably adapted for insertion and attachment to the bearing 2725. Theopposing end of the pin 2729 is attached to a cylindrical bracket 2728.Specifically, the cylindrical bracket 2728 defines a hole through alateral side of the bracket 2728 into which the pin 2729 is inserted.The pin 2729 is secured to the bracket 2728 by welding. Moreparticularly, the cylindrical bracket 2728 includes two matingsemi-circular members that, upon assembly, define a bore therethrough.The two semi-circular members are adapted to be connected to the lowerhorizontal arm of the pivot arm 2703 by separating the halves,positioning the halves about the lower horizontal arm of the pivot arm2703, and clamping the halves to the pivot arm 2703 by any suitablemeans. Specifically, the semi-circular members of the lower pivotbracket 2727 incorporate screws that pass through one semi-circularmember and tighten upon threads tapped into the opposing semi-circularmember.

The lower bearing assembly 2717 is configured as follows. The lowerpivot bracket 2727 is secured to the lower horizontal arm of the pivotarm 2703 such that the pin 2729 extends substantially vertically anddownwardly therefrom. The lateral position of the lower pivot bracket2727 along the lower horizontal arm of the pivot arm 2703 is dictated bythe size of the door to be rotated. The support bracket 2719 is clampedto the longitudinal members disposed below the vehicle supports of amain frame such that the tubular member 2721 extends transversely andoutwardly to the main frame. The lower bearing mount 2722 is clamped tothe tubular member 2721 such that the bearing portion 2724 is positionedsubstantially horizontally. The pin 2729 of the lower pivot bracket 2727is inserted into the bearing 2725.

As shown in FIG. 23, the upper and lower bearings 2709, 2725 must becoaxial with the axis of rotation of the door under test defined betweenthe door hinges 2726. As constructed and arranged, the outside door 90degree actuators 2700 provide adjustability in the horizontal planes ofboth upper and lower bearing assemblies 2705, 2717 to assure proper andindependent alignment of each bearing assembly. Specifically, the upperbearing assembly 2705 can be positioned laterally along the transversemember of the main frame by securing the upper bearing mount 2706 to theproper position on the transverse member. Once the lateral position ofthe bearing 2709 is secured, the transverse member can be shiftedlongitudinally and secured once the upper bearing 2709 is coaxial withthe axis of rotation of the door under test. Similarly, the lowerbearing assembly 2717 can be positioned laterally by moving and securingthe lower bearing mount 2722 along the tubular member 2721 of thesupport bracket 2719. The lower bearing assembly 2717 can be positionedlongitudinally by moving and securing the support bracket 2719 along thelongitudinal member of the main frame.

As also shown in FIG. 23, the vertical segment of the outside door arm2703 should be positioned laterally from the door handle nearer the axisof rotation to provide proper alignment for any outside door handleactuator attached to the outside door arm 2703.

As shown in FIG. 22, The outside arm actuator 2700 also includesmounting assemblies for the arm driver 2731. A first mounting assembly2733 for pivotal support of a rear portion of the actuator driver 2731comprises a tubular member 2735 welded or otherwise attached to a plate2737 such that the tubular member 2735 extends substantiallyperpendicular from the plate 2737. The plate 2737 defines a plurality ofholes therethrough spaced at a distance wider than the frame member towhich the first mounting assembly 2733 is to be attached. Preferably,the plate 2737 defines four holes therethrough spaced in a squareconfiguration. A clamp pad 2739, dimensionally similar to the plate 2737of the first mounting assembly 2733, is provided. The clamp pad 2739also defines a plurality of holes therethrough spaced identically as theplate 2737 of the first mounting assembly 2733 such that, upon assembly,the holes of both members align. The first mounting assembly 2733further comprises a cylindrical mounting bracket 2741 having acylindrical bracket 2743, as described above, and a mounting plate 2745extending therefrom. The cylindrical bracket 2743 comprises two mating,semi-circular members defining a bore therethrough adapted to clamp tothe tubular member 2735 of the first mounting assembly 2733. Themounting plate 2745 extends from the cylindrical bracket 2743 anddefines a hole therethrough through which an eye bolt 2747 is secured.The eye bolt 2747 provides a point of pivotal attachment for therearward portion of the arm driver 2731.

A second mounting assembly 2749 for pivotal support of a forward portionof the actuator driver 2731 comprises a cylindrical mounting bracket2751 having a cylindrical bracket 2753, as described above, and amounting plate 2755 extending therefrom. The cylindrical bracket 2753comprises two mating, semi-circular members defining a bore therethroughadapted to clamp to the upper horizontal member of the pivot arm 2703.The mounting plate 2755 extends from the cylindrical bracket 2753 anddefines a hole therethrough through which the forward portion of the armdriver 2731 can be attached pivotally by conventional means.

The first and second mounting assemblies 2733, 2749 are configured andpositioned as follows. As shown in FIG. 24, the outside door arm 2703 ispositioned at a mid cycle position. Fully opened and fully closedpositions are shown by broken lines. For example, if the door under testis to be cycled through 90 degrees, then the outside door arm 2703 isfirst positioned at 45 degrees relative to a closed door under test. Thesecond mounting assembly 2749 is secured to the pivot arm 2703 of theoutside door actuator 2700 at a position on the arm 2703 that willprovide the degree of opening or closing leverage required for theparticular door under test. Thereafter, the first mounting assembly 2733is mounted to a transverse member of a mainframe such that the tubularmember 2735 extends rearwardly therefrom and intersects with a line thatextends perpendicularly from the pivot arm 2703 at the mid cycleposition. The cylindrical mounting bracket 2741 of the first mountingassembly 2733 is secured to the tubular member 2735 such that the pivotpoint is on the extended perpendicular line.

Once the first and second mounting brackets 2733, 2749 are secured, thearm driver 2731 is secured to the mounting brackets 2733, 2749. The 90degree door actuator assembly 2700 is adapted for use with a lineardriver 2731. Any conventional driver or actuator having a strokesufficient to completely cycle the door may be used. If simulation ofhuman door opening or closing is to be achieved more precisely, however,the arm driver 2731 is preferably an electric linear actuator. Asuitable electric arm driver is the Industrial Devices Corporation H3301electric linear motion controller or equivalent.

As shown in FIGS. 25-28, the 90 degree outside door arm actuator 2700also includes interface assemblies 2757, 2767 disposed on the outsidedoor arm 2703 for engaging and opening or closing the door under test.As shown in FIG. 25, the closing interface assembly 2757 comprises aroller arm 2759, preferably constructed from steel tube, and a roller2761 rotatably attached at one end. More particularly, the roller arm2759 defines a hole through opposed surfaces of the tube positionedcross-axially in one end of the roller arm 2759. The roller 2761 ismounted rotatably to the arm 2759 by a mechanical fastener passingthrough the hole. The roller 2761 should have a diameter sufficientlylarge such that the roller 2761 extends past the end of the arm 2759.Preferably, the roller 2761 should be reasonably pliable; a suitableroller is a DURASOFT roller #DR-754-20 or equivalent.

The roller arm 2759 is attached to the outside door arm 2703 by twocylindrical brackets 2763 welded together such that the bores of eachbracket 2763 are aligned perpendicularly. The cylindrical brackets 2763are constructed as previously described. The roller arm 2759 is clampedwithin one of the cylindrical brackets 2763, and the other cylindricalbracket 2763 is secured to the outside door arm 2703 such that theroller arm 2759 extends towards the door under test. The roller arm 2759is positioned relative to the door arm 2703 and a bumper 2765 isextended from the main frame and engages the door arm 2703 when the doorarm 2703 is closed such that the roller 2761 is displaced from the doorunder test. The door arm 2703 should be controlled so that the door arm2703 does not crash into a fully closed and latched door under test. Thebumper 2765 provides a final fail safe to prevent such impact.

As shown in FIGS. 26-28, an opening interface assembly 2767 for theoutside door arm 2703 is adapted for attachment to the vertical memberof the outside door arm 2703. It provides a mechanism for selectivelyengaging a door and opening the door as the outside door arm 2703rotates in an opening direction. Specifically, the opening interfaceassembly 2767 comprises a pair of cylindrical brackets 2769 similar inconstruction to the previously defined cylindrical brackets. Thecylindrical brackets 2769 include two mating semicircular membersdefining a bore therethrough when positioned in the matingconfiguration. The cylindrical bracket 2769 is adapted to clamp to thevertical arm of the outside door arm 2703. A pair of bracket and bearingassemblies 2771 is attached, preferably by welding, to each of thecylindrical brackets 2769. More particularly, the pairs of cylindricalbearing brackets 2771 are welded on an outside surface of thecylindrical brackets 2769 and are positioned coaxially to each other. Ashaft 2773 is rotatably mounted within the bearing brackets 2771 suchthat each of the bearings is aligned coaxially. A piston engaging arm2775 is attached to the shaft 2773 between the pairs of bearings formingthe upper bracket end bearing assembly 2771. The piston engaging arm2775 defines a mounting hole at its free end for attachment to a piston2777 of an air cylinder 2779. Similarly, a first door engaging arm 2781is attached, preferably by welding to the shaft 2773 between the secondpair of bearings 2771. A cylindrical bracket 2783 identical to thepreviously described brackets is attached, preferably by welding to thefree end of the first door engaging arm 2781. A second door engaging arm2785 is clamped within the bracket 2783 of the first door engaging arm2781 and extends perpendicularly therefrom. A cylindrical bracket 2787,again of the previously described design, is fixed, preferably bywelding, to the free end of the second door engaging arm 2785. A thirddoor engaging arm 2789 is clamped within the cylindrical bracket 2787 ofthe second door engaging arm 2785. As configured, each of the doorengaging arms are substantially perpendicular to its adjoining arm, andthe first and third door engaging arms 2781, 2789 are substantiallyparallel. All of the door engaging arms are substantially coplanar.Thus, rotation of the piston engaging arm 2775 causes the shaft 2773 torotate about the bracket and bearing assemblies 2771 thereby causing thedoor engaging arms to rotate. A cylinder mounting plate 2791 isattached, preferably by welding to the upper cylindrical bracket 2769.An air cylinder 2779 is fixed to the plate 2791 such that its piston2777 extends towards the piston engaging arm 2775. The free end of theair cylinder piston 2777 is attached pivotally to the piston engagingarm 2775. One skilled in the art will recognize readily that anyactuator could be substituted for the air cylinder 2779 includingelectric cylinders and hydraulic cylinders.

The outside door actuators 2700 are provided preferably in three sizes;each being constructed and arranged identically except for the relativedimensions of the door arms and the output of the drivers. A small 90degree outside door actuator 2700 should be adapted for use with smalland compact vehicles. A medium 90 degree outside door actuator 2700should be adapted for use with large vehicles, and a large 90 degreeoutside door actuator 2700 should be adapted for use with full-sizevans.

Once the outside door actuator is aligned properly, as described above,and a door cycle has commenced (assuming the beginning of the cyclestarts from a closed position and the door latch has been released), thecylinder 2779 of the opening interface assembly 2767 retracts itsextensible piston 2777 to rotate the shaft 2773 in a counterclockwisedirection. Thereafter, the engaging arm 2789 engages and hooks onto thedoor under test. At this stage, the driver 2731 extends its piston torotate the door arm 2703 and, consequently, the door under test to afull open position. At the end of the opening cycle, the openinginterface assembly releases the door by retraction of the piston 2777.Thereafter, the driver 2731 retracts its piston and rotates the door arm2703 in a closing direction. The roller 2761 of the closing interfaceassembly engages the door and closes the door under test. The speedand/or acceleration of the retraction of the piston is controlled tosimulate human closure of the door. Once the door under test reaches thedesired closing speed, the driver 2731 slows down before impact with thedoor. Because the roller 2761 is not attached to the door under test,however, the door under test continues to rotate to closure.

Outside door actuator--180 degree rotation

An outside door, 180 degree actuator 2900 is configured to cycle doorsmounted for rotation about a vertical axis through approximately a 180degree rotation such as a rear van door. The 180 degree outside dooractuator 2900, generally, comprises an outside door arm 2903, a powereddriver 2943, support fixtures and brackets, bearings and bearing mounts,and interface members disposed between the door arm 2903 and thevertical door under test that are specifically designed for an openingor closing function.

As best viewed in FIGS. 29 and 30, an outside pivot arm 2903 isprovided. The pivot arm 2903 comprises two horizontal members disposedon opposing ends of a vertical member extending therefrom in the sameplane at right angles. The members are attached, preferably by welding,by any suitable means. As configured, the outside pivot arm 2903 forms ablock C-shape. Preferably, a stiffener member (not shown) is disposed ineach of the inside corners of the pivot arm 2903, and the pivot arm 2903is constructed from steel tubing.

The pivot arm 2903 is mountable to the main frame by an assembly ofbrackets and bearings. An actuator mounting assembly 2905 is selectivelyconnectable to the upper horizontal arm of the pivot arm 2903 and isselectively connectable to the main frame, providing an upper pivotpoint for the pivot arm 2903. Similarly, a lower bearing assembly 2917is selectively connectable to the lower horizontal arm of the pivot arm2903 and is selectively connectable to the main frame providing a lowerpivot point for the pivot arm 2903.

More particularly, as shown in FIGS. 31-33, the actuator mountingassembly 2905 includes an upper motor bracket 2907 comprising a set oflongitudinal support members 2909 fixed, preferably by welding, to topand bottom portions of a base plate 2911. A support plate 2908 is fixed,preferably by welding, to the base plate 2911 and extends horizontallytherefrom such that the plate 2908 is disposed between the upper andlower supports 2909. The longitudinal supports 2909 are fixed to theupper and lower surfaces of the support plate 2908, preferably bywelding. The lower longitudinal supports 2909 are spaced laterallyfurther apart than the upper longitudinal supports 2909, therebyproviding a space to mount an actuator 2943 between the lower supports2909 on the bottom surface of the support plate 2908 as described below.As configured, the top supports 2909 are disposed on the inside of thebottom supports 2909.

The height of the base plate 2911 is defined such that a plurality ofmounting holes can be spaced vertically at a distance greater than theheight of the horizontal member of the frame to which the actuatormounting assembly 2905 is attached. A mounting plate 2916 having aplurality of holes positioned identically to the holes of the base plate2911 is disposed on the opposing side of the frame member. The upperactuator bracket 2907 is mounted to the frame member by mechanicalfasteners that pass through the mounting holes of both plates.

As shown in FIG. 32, the actuator mounting assembly 2905 also comprisesa lower bracket 2913. The bracket 2913 includes a plate 2915 that isconfigured for connecting to a rotary actuator 2943 and defines aplurality of mounting holes as required by the actuator 2943. Twocylindrical brackets are fixed, preferably by welding, to the bottomsurface of the plate 2915 such that the brackets are disposedsymmetrically about the center of the plate 2915 and parallel to eachother. Each of the cylindrical brackets are constructed as thepreviously described cylindrical brackets. The brackets are adapted tobe positioned about and clamped to the upper horizontal arm of the pivotarm 2903 by any suitable means, thereby securing the lower bracket 2913to the outside pivot arm 2903.

The actuator mounting assembly 2905 is configured as follows. The uppermotor bracket 2907 is secured to the horizontal member or longitudinalmember of the frame, as required by any particular test, by positioningthe base plate 2911 and mounting plate 2916 about the frame member andclamping the plates to the member by any suitable means. Preferably, themounting bracket 2907 and mounting plate 2916 are oriented about thehorizontal frame member such that the bracket 2907 extends rearwardly ofthe rearward frame member and forwardly of the forward frame member. Aspreviously described, mechanical fasteners pass through the mountingplate 2916 and tighten upon the base plate 2911, thereby securing theupper motor bracket 2907 to the horizontal member of the frame. Themounting assembly 2905 can be similarly mounted to the longitudinalmember of the main frame. An outer housing of a bi-directional armactuator 2943, preferably an electric rotary actuator, is fastened tothe bottom of the support plate 2908 by any conventional means, securingthe actuator 2943 to the plate 2908. The lower bracket plate 2915 issecured to an inner housing of the arm actuator 2943, preferably byscrews that pass through the mounting holes defined in the plate 2915and tighten upon threads tapped into the inner housing of the actuator2943. The inner housing/plate interface provides the upper pivot for thedoor arm 2903. Finally, as previously described, the lower bracket 2913is secured to the pivot arm 2903 by the cylindrical brackets disposed onthe bottom of the plate 2915.

One skilled in the art will recognize that the actuator 2943 could beeither a linear actuator or a rotary actuator. Rotary actuators,however, have proven to provide the greatest angle of opening and are,therefore, preferred when 180 degree cycling is required. Additionally,one skilled in the art will recognize that any form of actuator could beincorporated including electric, hydraulic, or pneumonic actuators.Electric actuators are preferred, however, because they are lesssusceptible to temperature variations and provide a suitable platform bywhich velocity profiles of the actuator can be controlled. Velocityprofile control of the door arm 2903 is necessary to achieve simulationof human closure of vehicle doors.

A lower bearing assembly 2917 is provided. The lower bearing assembly2917 comprises in part a support bracket 2919, which includes acylindrical bracket constructed and arranged as previously describedcylindrical brackets. Specifically, the cylindrical bracket includes twomating, semi-circular members defining a bore therethrough when mated.The cylindrical bracket is adapted to be selectively connectable to thelongitudinal member disposed below the vehicle support of a main frame.A tubular member 2921 is welded or otherwise fixed to the cylindricalbracket and extends perpendicularly therefrom. The lower bearingassembly 2917 also includes a lower bearing mount 2923 having a mountingportion and a bearing portion preferably constructed from steel plate.The mounting portion comprises a cylindrical bracket as defined aboveadapted for connection to the tubular member 2921 of the support bracket2919. The bearing portion, a steel plate, is fixed to the mountingportion and extends therefrom such that the bearing portion ispositioned horizontally and provides a surface upon which a bearing 2925is mounted. Any conventional bearing 2925 adapted for the expected axialloads and cycle frequency may be incorporated.

The lower bearing assembly 2917 also comprises a lower pivot bracket2927. The lower pivot bracket 2927 comprises a pin 2929 having an endsuitably adapted for insertion and attachment to the bearing 2925. Theopposing end of the pin 2929 is attached to a cylindrical bracketconstructed and arranged as previously described cylindrical brackets.Specifically, the cylindrical bracket defines a hole through a lateralside of the bracket into which the pin 2929 is inserted. The pin 2929 issecured to the bracket by welding. The cylindrical bracket can bepositioned about and clamped to the lower horizontal member of the pivotarm 2903 by any suitable means, securing the pivot bracket 2927 to thepivot arm 2903.

The lower bearing assembly 2917 is configured as follows. The lowerpivot bracket 2927 is secured to the lower horizontal arm of the pivotarm 2903 such that the pin 2929 extends substantially vertically anddownwardly therefrom. The lateral position of the lower pivot bracket2927 along the lower horizontal arm of the pivot arm 2903 is dictated bythe size of the door to be rotated. The support bracket 2919 is clampedto the longitudinal members disposed below the vehicle supports of amain frame such that the tubular member 2921 extends transversely andoutwardly to the main frame when the upper mounting bracket 2907 ismounted to the longitudinal member of the main frame. Alternatively,when the upper mounting bracket 2907 is mounted to the rearward orforward frame members, the support bracket 2919 is clamped to thetransverse outside door arm frame. The lower bearing mount 2923 isclamped to the tubular member 2921 such that the bearing portion ispositioned substantially horizontally. The pin 2929 of the lower pivotbracket 2927 is inserted into the bearing 2925.

As shown in FIG. 30, the upper and lower door arm pivots must be coaxialwith the axis of rotation of the door under test. As constructed andarranged, the outside door 180 degree actuator 2900 providesadjustability in the horizontal planes of both the actuator mountingassembly 2905 and the lower bearing assembly 2917 to assure proper andindependent alignment of each door arm pivot. Specifically, the actuatormounting assembly 2905 can be positioned laterally along the horizontalmember of the rearward or forward frame member or the longitudinalmember by securing the upper motor bracket 2907 to the proper positionon the main frame. If required, once the lateral position of the upperpivot is secured, the position of the vehicle under test can be shiftedlongitudinally along the vehicle supports and laterally by adjustment ofthe vehicle supports and then secured once the upper pivot is coaxialwith the axis of rotation of the door under test. Similarly, the lowerbearing assembly 2917 can be positioned laterally by moving and securingthe lower bearing mount 2923 along the tubular member 2921 of thesupport bracket 2919. The lower bearing assembly 2917 can be positionedlongitudinally along the longitudinal member of the main frame by movingand securing the support bracket 2919 along the longitudinal member ofthe main frame. If the bearing assembly 2917 is mounted to thetransverse outside door arm frame, the bearing assembly 2917 can besimilarly positioned laterally.

The vertical segment of the outside door arm 2903 should be positionedlaterally from the door handle nearer the axis of rotation to provideproper alignment for any outside door handle actuator attached to theoutside door arm 2903.

The 180 degree outside door arm actuator 2900 also includes interfaceassemblies 2947, 2955 disposed on the outside door arm 2903 for engagingand opening or closing the door under test. As shown in FIG. 30, theclosing interface assembly 2947 comprises a roller arm 2949, preferablyconstructed from steel tube, and a roller 2951 rotatably mounted to oneend of the arm 2949. The end defines holes through opposed surfaces ofthe tube positioned cross-axially in end of the roller arm 2949. Theroller 2951 is mounted rotatably to the arm 2949 by a mechanicalfastener passing through the holes. The roller 2951 should have adiameter sufficiently large such that the roller 2951 extends past theend of the arm 2949. Preferably, the roller 2951 should be reasonablypliable; a suitable roller 2951 is a DURASOFT roller #DR-754-20 orequivalent.

The roller arm 2949 is attached to the outside door arm 2903 by twocylindrical brackets welded together such that the bores of each bracketare aligned perpendicularly. The cylindrical brackets are constructed aspreviously described. The roller arm 2949 is clamped within one of thecylindrical brackets, and the other cylindrical bracket is secured tothe outside door arm 2903 such that the roller arm 2949 extends towardsthe door under test.

A bumper 2953 is fixed to the main frame and extends therefrom such thatthe bumper 2953 engages the door arm 2903 when the door arm 2903 isclosed thereby positioning the roller 2951 away from the door undertest. The door arm 2903 should be controlled, as described in moredetail below, so that the door arm 2903 does not crash into a fullyclosed and latched door under test. The bumper 2953 provides a finalfail safe to prevent such impact.

As shown in FIGS. 34-36, an opening interface assembly 2955 for theoutside door arm 2903 is adapted for attachment to the vertical memberof the outside door arm 2903. It provides a mechanism for selectivelyengaging a door and opening the door as the outside door arm 2903rotates in an opening direction. Specifically, the opening interfaceassembly 2955 comprises a pair of cylindrical brackets similar inconstruction to the previously defined cylindrical brackets. Thecylindrical brackets include two mating semi-circular members defining abore therethrough when positioned in the mating configuration. Thecylindrical bracket is adapted to clamp to the vertical arm of theoutside door arm 2903. A pair of bracket and bearing assemblies 2957 isattached, preferably by welding, to each of the cylindrical brackets.More particularly, the pairs of cylindrical bearing brackets 2957 arewelded on an outside surface of the cylindrical brackets and arepositioned coaxially to each other. A shaft 2959 is rotatably mountedwithin the bearings such that each of the bearings is aligned coaxially.A piston engaging arm 2961 is attached to the shaft 2959 between thepairs of bearings forming the upper bracket end bearing assembly 2957.The piston engaging arm 2961 defines a mounting hole at its free end forattachment to a piston 2963 of an air cylinder 2965.

Similarly, a first door engaging arm 2967 is attached, preferably bywelding to the shaft 2959 between the second pair of bearings formingthe lower bracket end bearing assembly 2957. A cylindrical bracketidentical to the previously described brackets is attached, preferablyby welding to the free end of the first door engaging arm 2967. A seconddoor engaging arm 2969 is clamped within the bracket of the first doorengaging arm 2967 and extends perpendicularly therefrom. A cylindricalbracket, again of the previously described design, is fixed, preferablyby welding, to the free end of the second door engaging arm 2969. Athird door engaging arm 2971 is clamped within the cylindrical bracketof the second door engaging arm 2969. As configured, each of the doorengaging arms are substantially perpendicular to its adjoining arm, andthe first and third door engaging arms 2967, 2971 are substantiallyparallel. All of the door engaging arms are substantially co-planar.Thus, rotation of the piston engaging arm 2961 causes the shaft 2959 torotate about the bracket and bearing assemblies 2957 thereby causing thedoor engaging arms to rotate. A cylinder mounting plate 2966 isattached, preferably by welding to the upper cylindrical bracket. An aircylinder 2965 is fixed to the plate 2966 such that its piston 2963extends towards the piston engaging arm 2961. The free end of the aircylinder piston 2963 is attached pivotally to the piston engaging arm2961. One skilled in the art will recognize readily that any actuatorcould be substituted for the air cylinder 2965 including electriccylinders and hydraulic cylinders.

The outside door actuators 2900 are provided preferably in three sizes;each being constructed and arranged identically except for the relativedimensions of the door arms 2903 and the output of the drivers 2943. Asmall 180 degree outside door actuator 2900 should be adapted for usewith small and compact vehicles. A medium 180 degree outside dooractuator 2900 should be adapted for use with large vehicles, and a large180 degree outside door actuator 2900 should be adapted for use withfull-size vans.

Once the 180 degree, outside door actuator is aligned properly, asdescribed above, and a door cycle has commenced (assuming the beginningof the cycle starts from a closed position and the door latch has beenreleased), the cylinder 2965 of the opening interface assembly 2955retracts its extensible piston 2963 to rotate the shaft 2959 in acounterclockwise direction. Thereafter, the engaging arm 2971 engagesand hooks onto the door under test. At this stage, the driver 2943rotates the door arm 2903 and, consequently, the door under test to afull open position. At the end of the opening cycle, the openinginterface assembly releases the door by retraction of the piston 2963.Thereafter, the driver 2943 rotates the door arm 2903 in a closingdirection. The roller 2951 of the closing interface assembly engages thedoor and closes the door under test. The speed and/or acceleration ofthe driver 2943 is controlled to simulate human closure of the door.Once the door under test reaches the desired closing speed, the driver2943 slows down before causing the arm 2903 to impact the door. Becausethe roller 2951 is not attached to the door under test, however, thedoor under test continues to rotate to closure.

Inside door actuator--90 degree rotation

The inside door 90-degree actuators 3100 are configured to cycle doorsmounted for rotation about a vertical axis through approximately 90degrees. The 90-degree inside door actuators 3100 cycle doors under testfrom a position inside the vehicle under test. The 90-degree inside dooractuators 3100, generally, comprise a linkage mechanism 3102, a powereddriver 3104 for rotating the linkage mechanism 3102, support fixturesand brackets, bearings and bearing mounts, and interface membersdisposed on the linkage assembly specifically designed for an opening orclosing function.

As shown in FIGS. 37-38, a rear driver mount 3106 is provided. Thedriver mount 3106 comprises a plate 3108 defining a plurality of holestherethrough. The plurality of holes provides a convenient place forattaching the plate 3108 to an inside base frame 900 by mechanicalfasteners. A tubular member 3110 is fixed, preferably by welding to theplate 3108 such that the tubular member 3110 extends perpendicularlyfrom the plate 3108. A pair of cylindrical brackets 3112 constructed andarranged as previously described are joined together, preferably bywelding, such that the longitudinal axes of the brackets are disposedperpendicularly relative to each other. One of the cylindrical bracketsis clamped to the tubular member 3110 of the driver mount 3106 such thataxis of the other bracket is positioned perpendicular to the tubularmember 3110. A second tubular member 3114 is secured in the secondcylindrical bracket such that the second tubular member 3114 extendsperpendicularly relative to the first tubular member 3110. Asconfigured, the relative height and lateral position of the secondtubular member 3114 of the driver mount 3106 can be changed by shiftingthe positions of the cylindrical clamps along the first tubular member3110 and the second tubular member 3114 within the cylindrical clamps,respectively. Finally, a rod end 3116 is fixed to one end of the secondtubular member 3114 to provide an attachment mechanism for attaching thedriver mount 3106 to a driver 3104.

The actuator driver 3104 is fixed pivotally to the rod end 3116 byconventional means. Preferably, the driver 3104 is an electric linearactuator having an extensible piston. One skilled in the art willrecognize readily that other drivers, including hydraulic cylinders orair cylinders, could be incorporated herein. However, electric linearactuators are most suitably adapted for control of the door actuator3100. Simulation of human closure of vehicle doors requires that thedoor actuators follow a velocity profile indicative of human doorclosure. Electric actuators are best suited for such control. Bycomparison, hydraulic and air actuators are less responsive to precisecontrol and are subject to varied outputs as temperature varies.

A bearing mount assembly 3118 is configured for attachment to the insidebase frame 900 and is adapted to position the linkage assembly 3102 inproper position relative to the door under test. More particularly, thebearing mount assembly 3118 comprises a base plate 3120. The base plate3120 defines two parallel slots 3122 disposed along the edges of theplate 3120. The slots 3122 provide a convenient place to attach theplate 3120 to an inside base frame 900. Moreover, the slots provide theability to position the base plate 3120 laterally along the inside baseframe 900 by sliding the plate 3120 relative to the mechanical fastenerspassing through the slots 3122. A tubular member 3124 is fixed,preferably by welding to the plate 3120 such that the tubular member3124 extends perpendicularly from the plate 3120. Preferably, astiffener member 3126 is disposed, preferably attached by welding,between the member 3124 and the plate 3120.

A bearing mount 3130 is provided for pivotal attachment of bearings tothe tubular member 3124. A plate 3132 is mounted to a cylindricalbracket 3134 (constructed and arranged as described above) clamped tothe tubular member 3124. The plate 3132 can be selectively pivoted aboutan axis perpendicular to the tubular member 3124. Conventional means areused to secure the plate 3132 in the selected angular position. A firstpair of bearings 3136 and a second pair of bearings 3138 are disposed onthe plate 3132. Any bearing suitable for the expected loads andfrequency of rotation may be incorporated in this assembly. A McGillTBC-25 bearing or equivalent may be used.

A first linkage member 3140 and a second linkage member 3142 arerotatably mounted at one end to the bearings 3136, 3138 such that themembers 3140, 3142 extend therefrom. A cam bracket 3144 is attached tothe other ends of the linkage members 3140, 3142 such that the members3140, 3142 are positioned parallel to each other and are confined tomaintain such parallel relationship as they rotate. More particularly, acam follower 3146 is rotatably mounted to each end of the members 3140,3142. In turn, the cam followers 3146 rolls within the cam bracket 3144.A suitable cam follower is the RBC # H-24-LW. As configured, the linkagemembers 3140, 3142 are confined to parallel rotation.

A plurality of rail supports 3148 is disposed on the first linkagemember 3140. Each of the rail supports 3148 defines a slot therethrough.Mechanical fasteners passing through the slots of the rail supportsattach the rail supports 3148 to the first linkage member 3140. Asconfigured, the rail supports can slide relative to their associatedfastener until such fastener secures the supports 3148 to the member3140. A linear slide 3150 is mounted to the rail supports 3148 such thatthe linear slide 3150 can be selectively positioned relative to the doorunder test. A roller and shaft assembly 3149 is slidably mounted to thecam bracket 3144.

A forward driver bracket 3152 is mounted to the second linkage member3142. The forward bracket 3152 provides a point of pivotal attachmentfor the forward end of the driver 3104.

As shown in FIGS. 39-43, the actuator 3100 is configured as follows. Asshown in FIG. 39, the bearing mount 3130 is positioned relative to theinside base frame 900 such that the centers of the bearings 3136, 3138are co-linear with the door hinge 3137. As shown in FIG. 40. the rollerand shaft assembly 3149 is positioned relative to a closed door undertest such that an imaginary line 3154 extending between the axis of doorrotation and the center of the roller 3149 is parallel with the firstand second linkage members 3140, 3142. As configured, the members 3140,3142 and the imaginary line 3154 will remain parallel in all positionsof rotation and dimension A, B and C are equal. As shown in FIG. 41, thebearing plate 3132 is pivoted to a position wherein the axes of thebearings 3136, 3138 are parallel with the axis of door rotation. Asconfigured, the roller 3149 will not change its position relative to thedoor under test--i.e., it will not roll up and down or fore and aft. Asshown in FIG. 42, the door under test is positioned in its mid-cycleposition. The linear actuator 3104 is pivotally mounted between theforward bracket 3152 and a rear mount 3156 such that the actuator 3104is perpendicular to the members 3140, 3142. The forward mount 3152 ispositioned laterally on the second linkage member 3142 to provide asufficient lever arm to rotate the door under test. Finally, as shown inFIG. 43, the linear slide 3150 is positioned parallel to the door undertest when the door is in a closed position. As configured, the linearslide 3150 remains a constant distance from the door under test in allpositions of rotation of the linkage assembly 3102. Preferably, a bumperassembly 3160 is disposed behind the linkage members 3140, 3142 toprevent over-rotation of the members 3140, 3142.

As configured, the roller 3149 pushes the door under test in an openingdirection as the actuator 3104 pushes the linkage members 3140, 3142 torotation in an opening direction. To effect door closure, a strap andhook assembly 3162 is fixed to the linear slide 3150. A hook of thestrap and hook assembly 3162 is attached to a door handle of the doorunder test. As the linkage members 3140, 3142 are rotated by theactuator 3104 in a closing direction, the strap and hook assembly pullsthe door under test closed.

Inside door actuator--120 decree rotation The inside door 120-degreeactuators 3300 are configured to cycle doors mounted for rotation abouta vertical axis through approximately 120 degrees. As the name implies,the 120-degree inside door actuators 3300 cycle doors under test from aposition internal to the vehicle under test. As shown in FIG. 44, the120-degree inside door actuators 3300, generally, comprise a linkagemechanism 3302, a powered driver 3304 for rotating the linkage mechanism3302, support fixtures and brackets, bearings and bearing mounts, andinterface members disposed on the linkage assembly specifically designedfor an opening or closing function.

As shown in FIG. 45, a driver mount 3306 is provided. The driver mount3306 comprises a plate 3308 defining a plurality of holes therethrough.The plurality of holes provides a convenient place for attaching theplate 3308 to an inside base frame 900 by mechanical fasteners. Atubular member 3310 is fixed, preferably by welding to the plate 3308such that the tubular member 3310 extends perpendicularly from the plate3308. A pair of cylindrical brackets 3312 constructed and arranged aspreviously described are joined together, preferably by welding, suchthat the longitudinal axes of the brackets are disposed perpendicularlyrelative to each other. One of the cylindrical brackets is clamped tothe tubular member 3310 of the driver mount 3306 such that axis of theother bracket is positioned perpendicular to the tubular member 3310. Asecond tubular member 3314 is secured in the second cylindrical bracketsuch that the second tubular member 3314 extends perpendicularlyrelative to the first tubular member 3310. As configured, the relativeheight and lateral position of the second tubular member 3314 of thedriver mount 3306 can be changed by shifting the positions of thecylindrical clamps along the first tubular member 3310 and the secondtubular member 3314 within the cylindrical clamps, respectively.Finally, a rod end 3316 is fixed to one end of the second tubular member3314 to provide an attachment mechanism for attaching the driver mount3306 to a driver 3304.

The actuator driver 3304 is fixed pivotally to the rod end 3316 byconventional means. Preferably, the driver 3304 is an electric linearactuator having an extensible piston. One skilled in the art willrecognize readily that other drivers, including hydraulic cylinders orair cylinders, could be incorporated herein. However, electric linearactuators are most suitably adapted for control of the door actuator3300. Simulation of human closure of vehicle doors requires that thedoor actuators follow a velocity profile indicative of human doorclosure. Electric actuators are best suited for such control. Bycomparison, hydraulic and air actuators are less responsive to precisecontrol and are subject to varied outputs as temperature varies.

As shown in FIG. 44, a pivot bearing mount assembly 3318 is configuredfor attachment to the inside base frame 900 and is adapted to positionthe linkage assembly 3302 of the door actuator 3300 in proper positionrelative to the door under test. More particularly, the pivot bearingmount assembly 3318 includes a first base plate 3320. The first baseplate 3320 includes a plurality of linear slots 3322 for mounting thebase plate 3320 to the inside base frame 900. The first base plate 3320is mounted to the inside base frame by mechanical fasteners that passthrough the slots 3322 and attach to the threaded holes of the insidebase frame 900. The first base plate 3320 can be positioned laterallyrelative to the side of a vehicle under test by sliding the first baseplate 3320 relative to the inside base frame 900 along the slots 3322.This direction of adjustment is conveniently called the "Y" adjustment.

A second base plate 3324 is slidably mounted to the first base plate3320. Specifically, the second base plate 3324 defines a pair of slots3326 extending perpendicularly to the slots 3322 of the first base plate3320. Mechanical fasteners passing through the slots 3326 of the secondbase plate 3324 attach to threaded holes in the first base plate 3320.As configured, the second base plate 3324 can slide relative to thefirst base plate 3320 in a direction perpendicular to the slots 3322 ofthe first base plate 3320. This direction of adjustment is convenientlycalled the "X" adjustment. Thus, the pivot bearing mount assembly 3318can be positioned in the "Y" direction relative to the width of theinside base frame 900 and positioned in the perpendicular "X" directionrelative to the length of the inside base frame 900 by moving the baseplates 3320, 3324 in their respective slots 3322, 3326. Adjustment inthe "Y" direction would move the pivot bearing mount assembly 3318towards or away from the door under test. Adjustment in the "X"direction would move the pivot bearing mount assembly 3318 substantiallyparallel with the door under test.

A vertical plate member 3328 of the second base plate 3324 is fixed,preferably by welding, to a lateral edge 3330 of the second base plate3324 displaced from the slots 3326 and extends perpendicularlytherefrom. The vertical member 3328 has a width smaller than the widthof the lateral edge 3330 of the second base plate 3324. A stiffenermember 3332 is disposed, preferably fixed by welding, between thevertical member 3328 and the second base plate 3324 and extendsperpendicularly from both the vertical member 3328 and the second baseplate 3324. The vertical member 3328 defines a pair of vertical slotsdisposed near each vertical edge of the vertical member 3328. One of thepair of slots has a width greater than the other slot. A bearing mount3334 comprised of L-shaped channel is pivotally mounted to the verticalmember 3328 of the second base plate 3324. The bearing mount 3334defines a plurality of holes at each lateral end for mounting a bearingassembly 3336. Disposed between the bearing mount holes are a pluralityof holes spaced for alignment with the slots of the vertical member3328. The bearing mount 3334 is fixed to the vertical member 3328 bymechanical fasteners passing through the holes of the bearing mount 3334and the slots of the vertical member 3328. The slots of the verticalmember 3328 are configured to allow the bearing mount 3334 to slidevertically relative to the vertical member 3328 and provide some degreeof rotation of the bearing mount 3334 relative to the vertical member3328. As configured, the bearing mount assembly 3318 can be positionedin three dimensional space relative to the inside base frame 900, andconsequently the door under test, by the relative movement of the platesalong the slots provided in each of the members. Bearings 3336 aremounted to each end of the bearing mount 3334. Any bearing suitable forthe expected loads and frequency of cycling may be incorporated. Asuitable bearing for this application is the Sealmaster TB-8 orequivalent. The bearings 3336 are mounted such that their axes ofrotation are perpendicular to the first base plate 3320.

As best viewed in FIG. 45, the linkage assembly 3302 comprises a pair oftriangular members 3340, 3342. Both of the triangular members areconstructed and arranged as identical isosceles triangles having bases3344, 3346 and apex angles 3348, 3350 opposed to the bases 3344, 3346.Again, the dimensions of the bases and apex angles are the same for bothtriangular members 3340, 3342. The triangular member 3340 disposednearest the door under test is labelled conveniently as the outsidetriangular member 3340, and the triangular member 3342 disposed farthestfrom the door under test is labelled conveniently as the insidetriangular member 3342. As discussed below, each angle of the triangularmembers provides a pivot point for the linkage assembly 3302. As oneskilled in the art will recognize readily upon further review of thisdescription, the triangular members are conveniently constructed in atriangular shape and could, however, be constructed in any othergeometric shape as long as three pivot points are maintained.

A bearing 3352 (or more precisely labeled as bearings 3354, 3356, 3358as shown in the drawings) is disposed at each end of the bases 3344,3346 of the triangular members 3340, 3342. Any bearing suitable for theexpected loads and frequency of door cycling and having the capabilityto be attached to another linkage member may be used. A suitable bearingfor this application is a Torrington DW6 bearing or equivalent. The apexangle portions 3348, 3350 of the triangular members 3340, 3342 arerotatably mounted to the bearings 3336 of the bearing mount assembly3318. As configured, the triangular members 3340, 3342 are rotatablewithin the same plane.

A pair of straight linkage members 3360, 3362 are disposed on thetriangular linkage members 3340, 3342. More particularly, a firststraight linkage member 3360 is pivotally mounted to the bearings 3336of the triangular linkage member 3340 such that one end 3364 of thefirst straight linkage member 3360 is pivotally mounted to the bearing3354 of the base 3346 of the inside triangular member 3342 and such thatthe straight linkage member 3360 is pivotally mounted at an intermediateposition to the bearing 3352 of the base 3344 of the outside triangularmember 3340. As configured, the first straight linkage member 3360includes the opposite end 3368 extending past the inside triangularmember 3340. Additionally, the connection of the first straight linkagemember 3360 to the triangular members 3340, 3342 fixes the relativeposition between the triangular members during all points of rotation.Similarly, a second straight linkage member 3362 is disposed pivotallyon the triangular members 3340, 3342. Specifically, one end 3370 of thesecond straight linkage member 3362 is pivotally mounted to the bearing3358 of the base 3346 of the inside triangular member 3342. The secondstraight linkage member 3362 is pivotally mounted at an intermediateposition to the bearing 3356 of the base 3344 of the outside triangularmember 3340. As configured, the second straight linkage member 3362 isdisposed parallel in all positions of rotation relative to the firststraight linkage member 3360. Similarly, the second straight linkagemember 3362 includes an outside opposite end 3372 extending from theinside triangular member 3340. This configuration assures that the bases3344, 3346 of the inside and outside triangular members 3340, 3342maintain the same angular relationship to each other and that therelative distance between the bases 3344, 3346 of the triangular members3340, 3342 remains constant for all points of rotation. Additionally,the straight linkage members 3360, 3362 remain parallel in all points ofrotation.

A bearing 3374 is disposed in each outside end 3368, 3372 of thestraight linkage members 3360, 3362. Again, any bearing suitable for theexpected loads and frequency of cycling may be incorporated in thislinkage. A Torrington DW-6 bearing or equivalent is suitable for thisapplication. A linkage bar 3376 is pivotally disposed between theoutside end bearings 3374. As configured, the linkage bar 3376 isparallel with the bases 3344, 3346 of the triangular linkage members3340, 3342 and equal in width to the bases. In fact, the linkage bar3376 forms a base of an imaginary isosceles triangle 3378 having an apexangle 3380 opposite the linkage bar 3376. The imaginary triangle 3378 isidentical in size and angle with the triangular members 3340, 3342. Theimaginary triangle 3378 and the triangular members 3340, 3342 arecoplanar and have their respective apex angles positioned linearly fromeach other.

As configured, each triangle is rotatable about its respective apexangle. In fact, the actuator 3300 should be positioned on the insidebase frame 900 relative to the door under test such that the apex angle3380 of the imaginary triangle 3378 is coaxial with the axis of rotationof the door under test and such that the plane of the triangular members3340, 3342 is perpendicular to the axis of door rotation. Such aconfiguration assures that the linkage bar 3376 follows the arc ofrotation of the door under test. Consequently, any member extending fromthe linkage bar 3376 to engage the door under test will contact the doorunder test at one point only for all positions of rotation. The apexangle 3380 of the imaginary triangle 3378 is positioned coaxially withthe axis of door rotation by sliding the base plates along their slotsand rotating, if required, the bearing mount plate 3334.

A contact mount plate 3382 is fixed to the bar linkage 3376 byconventional means. The contact mount plate 3382 provides a convenientbase to which opening or closing assemblies may be attached. Again, anymember extending from the contact mount plate 3382 will contact the doorunder test in only one position for all points of rotation. A closingassembly 3384 for pulling the door closed is provided. The closingassembly 3384 comprises a strap (not shown) fixed to the contact plate3382 by conventional means. At the opposed end of the strap, a hook 3386for grabbing a pull cup of a door handle is disposed. As the actuator3300 rotates in a closing direction, the closing assembly 3384 pulls thedoor under test closed. An opening assembly 3388 is also provided. Theopening assembly 3388 comprises a shaft and roller assembly 3390. Aroller 3392 is disposed rotatably to an end of a shaft 3394 byconventional means. A suitable roller for this application is a DurasoftDR-754-20 or equivalent. The shaft 3394 is mountable to the contactmount plate 3382 by clamps 3396 fixed to the contact mount plate 3382.Such a configuration provides flexibility in positioning the roller 3392relative to the door under test.

As described above, an electric linear actuator 3304 drives thetriangular members 3340, 3342 to rotate in either an opening or closingdirection. In that regard, a tubular member 3400 is disposed on theinside triangular member 3342 such that the tubular member 3400 issubstantially coextensive with a line extending perpendicularly from thebase 3346 of the inside triangular member 3342 and intersecting the apexangle 3350 of the inside triangular member 3342. The tubular member 3400is fixed to the triangular member 3342 by conventional means. A forwardcylinder mount 3402 is mountable selectively to any position along thetubular member 3400. The forward cylinder mount 3402 comprises acylindrical bracket 3404 constructed and arranged as those previouslydescribed. A mount plate 3406 is fixed, preferably by welding, to alateral side of the cylindrical bracket 3404 and extends perpendicularlyfrom the axis of the cylindrical bracket 3404. The plate 3406 provides apoint of pivotal attachment for the electric actuator 3304.

The actuator 3304 is attached as follows. The triangular members 3340,3342 are positioned in a mid-cycle position--i.e., at a positioncorresponding to a door half way opened. The forward cylinder mount 3402is secured to the tubular member 3400 of the inside triangular member3342 at a position that will provide the necessary lever arm incombination with the load applied by the linear driver 3304 to rotatethe door under test. With the triangular members 3340, 3342 in themid-cycle position, the linear actuator 3304 is pivotally mounted to theforward cylinder mount 3402 and is extended perpendicularly from thetubular member 3400. The rear of the linear actuator 3304 is thereafterpivotally mounted to the cylinder mount 3306, and the cylinder mount3306 is fixed to the inside base frame 900.

In operation, assuming the door under test is initially in a fullyclosed position, the door under test is first unlatched (any mechanismthat can unlatch the door, including those described below, may beincorporated). Once the system receives confirmation that the door isunlatched, the linear actuator 3304 extends its piston to rotate thelinkage assembly 3302 in an opening direction. The roller 3392 engagesthe door under test and pushes it open. Again, because of thearrangement of the linkage members as described above, the roller 3392contacts the door under test at a single point for the entire rotationof the door. Once the door reaches its fully opened position, theelectric linear actuator 3304 retracts its piston and rotates thelinkage assembly 3302 in a closing direction. In turn, the strap andhook assembly pulls the door closed.

Inside door actuator--180 decree rotation

The inside door, 180-degree actuators 3500 are configured to cycle doorsmounted for rotation about a vertical axis through approximately 180degrees. The 180-degree inside actuators 3500 are adapted particularlyto rotate, for example, rear and side van doors. The actuators 3500cycle doors under test from a position inside the vehicle under test.The 180-degree inside door actuator 3500 comprises generally a linkageassembly 3502, a power driver 3504 for rotating the linkage assembly3502, support fixtures and brackets, bearings and bearing mounts, andinterface members disposed on the linkage assembly 3502 specificallyadapted for a opening or closing function.

As shown in FIG. 46, a driver base plate 3506 is provided. The driverbase plate defines 3506 a plurality of holes through the plate 3506providing points of attachment for a driver 3504 to the base plate 3506.The plurality of holes is, of course, arranged to align with mountingpoints on the driver 3504 selected for this actuator 3500. The driverbase plate 3506 also defines a plurality of slots 3508 through the plate3506 in each of the corners of the plate 3506. The plurality of slots3508 provides the points of attachment of the driver base plate 3506 toan inside base frame 900. Specifically, mechanical fasteners passthrough the slots 3508 and attach to the inside base frame 900 fixingthe driver base plate 3506 to the inside base frame 900 when secured.The slots 3508 also allow lateral positioning of the driver base plate3506 relative to the inside base frame 900.

The actuator driver 3504 is fixed to the driver base plate 3506 byconventional means. Preferably, the driver 3504 is a reversible electricrotary motor. One skilled in the art will recognized readily that otherdrivers could be incorporated herein. However, rotary motors generallyprovide the greatest effective degree of rotation. Moreover, electricrotary motors are most suitably adapted for control of the door actuator3500. Simulation of human closure of vehicle doors requires that thedoor actuators follow a velocity profile indicative of human doorclosure. Electric actuators are best suited for such control. Hydraulicand pneumatic actuators are less responsive and are subject to variedoutputs as temperature varies.

A sprocket and shaft assembly 3510 is fixed to the center of theelectric rotary motor 3504 and aligns coaxially with the rotational axisof the motor. The sprocket and shaft assembly 3510 extends from thecenter of the motor 3504 such that the plane of the sprocket 3512 isparallel with the plane of the driver base plate 3506. The sprocket3512, however, is fixed and does not rotate under the influence of themotor 3504.

As best viewed in FIGS. 46 and 47, the linkage assembly 3502 comprises arotating plate 3514 adapted to be connected to the electric rotary motor3504. At one end of the rotating plate 3514, a centrally located hole3516 is defined through which the sprocket 3512, rotationally fixedrelative to the axis of the electric motor 3504, passes. A plurality ofholes 3518 is defined around the periphery of the hole 3516 and providespoints of attachment of the rotating plate 3514 to the electric motor3504. The position of the holes 3518 is, of course, defined by therequirements of the driver selected for this actuator.

At the other end of the rotating plate 3514, a pair of freely rotatingsprockets 3520 is provided. Each of the sprockets 3520 is attached tothe rotating base plate 3514 by conventional means such that eachsprocket 3520 is coplanar with each other and both are coplanar with thesprocket 3512 disposed coaxially with the motor axis. As configured,each sprocket 3520, 3512 defines a point of an isosceles triangle 3524;the centers of the freely rotating sprockets 3520 define the base 3522of the isosceles triangle 3524, and the center of the fixed sprocket3512 is positioned at the apex angle 3526 of the isosceles triangle 3524opposite the base 3522.

A chain 3528 is disposed around the sprockets 3520, 3512 andsubstantially outlines the isosceles triangle 3524. Preferably, a chaintensioner 3530 is disposed in engaging relationship with the chain 3528and keeps the chain 3528 under proper tension. As configured, therotating plate 3514 rotates in response to the rotation of the electricrotary motor 3504. Since the fixed sprocket 3512 is fixed and unable torotate, the chain 3528 remains fixed as well. The pair of freelyrotating sprockets 3520 rotates in an orbit about the center of themotor 3504. Because the freely rotating sprockets 3520 are free torotate about their respective axes, however, the freely rotatingsprockets 3520 roll along the fixed chain 3528. Thus, the freelyrotating sprockets 3520 both orbit about the motor center and rotateabout their respective axes.

As one skilled in the art will recognize readily, the chain 3528 andtensioner 3530 could be replaced with a bar linkage. In that regard, anyassembly that provides both the overall orbital rotation of the freelyrotating sprockets 3520 (i.e., the base of the isosceles triangle) andthe local rotation of the sprockets 3520 can be incorporated in thisactuator.

A parallel linkage member 3532 is fixed to each of the freely rotatingsprockets 3520 such that the pair of parallel linkage members 3532extends in parallel relationship from each of the freely rotatingsprockets 3520. As configured, each of the parallel linkage members 3532rotates about the center of its respective sprocket 3520 as thesprockets 3520 roll along the fixed chain 3528 as the rotating plate3514 rotates. Additionally, the parallel linkage members 3532 rotateabout the center of the motor 3504 as the sprockets 3520 orbit about themotor center. A door-engaging linkage member 3534 is fixed to the endsof the parallel linkage members 3532 opposite the freely rotatingsprockets 3520. More particularly, such ends of the parallel linkagemembers 3532 are mounted pivotally to the door engaging linkage member3534. A roller bearing 3536 suitable for the expected loads andfrequency of cycling is fixed to one end of the engaging linkage member3534. A second roller bearing 3538 is fixed to the engaging linkagemember 3534 spaced laterally from the first roller bearing 3536 suchthat the distance between the roller bearings 3536, 3538 equals thedistance between the freely rotating sprockets 3520. The ends of theparallel linkage members 3532 are rotatably mounted to the rollerbearings 3536, 3538 such that the parallel linkage members 3532 remainparallel in all positions of rotation. The parallel linkage members 3532are mounted to the roller bearings 3536, 3538 by conventional means.

Preferably, the parallel linkage members 3532 are not coplanar. One ofthe parallel linkage members 3532 is mounted above the door engaginglinkage member 3534, while the other is mounted below the engaginglinkage member 3534. Such a configuration allows the maximum rotation ofthe linkage assembly 3502.

As all of the door actuation modules are configured, the 180-degreeinside door actuator 3500 must be mounted in proper relationship to theaxis of rotation of the door under test. Specifically, the rollerbearings 3536, 3538 of the door engaging linkage member 3534 define abase 3540 of a second isosceles triangle 3542. The second isoscelestriangle 3542 is identical in size and shape with the first isoscelestriangle 3524. Thus, the second isosceles triangle 3542 includes an apexangle 3544 of an identical size but laterally spaced from the first apexangle 3526. The point of the second isosceles triangle 3542 defining theapex angle 3544 must be coaxial with the axis of rotation of the doorunder test. Moreover, the plane containing the isosceles triangles 3524,3542 must be perpendicular to the axis of rotation of the door undertest. The isosceles triangles 3524, 3542 can be positionedperpendicularly to the axis of door rotation by shims (not shown)disposed between the motor base plate 3506 and the inside base frame900.

As configured, the second isosceles triangle 3542 rotates about the axisof door rotation such that each point on the base 3540 (i.e., thesection of the door engaging linkage member between the roller bearings)traces out an arc. Similarly, the base 3522 of the first isoscelestriangle 3524 (i.e., the space between the freely rotating sprockets)traces out an identical, though laterally displaced, arc as the motorrotates. In other words, the base 3522 of the first isosceles triangle3524 rotates about the motor 3504 in an arc identical but displaced tothe arc of rotation of the base 3540 of the second isosceles triangle3542. Thus, once the actuator 3500 is aligned properly with the dooraxis of rotation, all points on the door-engaging linkage member 3534rotate coaxially with the door under test. Consequently, any contactbetween the door-engaging linkage member and the door under test doesnot shift as the door is rotated. This configuration allows the dooractuator 3500 to engage a door under test at a single location on thedoor for all points of door rotation and prevents relative motionbetween the door under test and the door-engaging linkage member 3534.

As shown in FIG. 46, the door-engaging linkage member 3534 extendslaterally from the roller bearings 3536, 3538. This additional lengthprovides suitable points for attaching door interface assemblies. As oneskilled in the art will recognize readily, the 180-degree inside dooractuator 3500 can be adapted to open or close vertically hinged doorsfrom an inside position. A door opening assembly 3550 comprises a roller3552 mounted rotatably to one end of an arm 3554. Any roller that canengage a door without imparting damage thereto may be incorporated. Afour inch roller is preferred for this application. The other end of thearm 3554 defines a slot 3556 through which a mechanical fastener passesand fixes the roller arm 3554 to the door-engaging linkage member 3534.The slot 3556 provides both linear and rotational positioning of theroller 3552 relative to the door-engaging linkage member 3534. As thedoor-engaging linkage member 3534 rotates, the roller 3552 engages thedoor under test and pushes it open.

Several door closing assemblies are provided. As shown in FIG. 47, afirst door closing device 3560 comprises a strap and hook assembly thathooks onto a door handle of the door under test. One end of the strap isfixed to the door-engaging linkage member 3534 by a clamp plate 3562.The strap is disposed between the clamp 3562 and the door-engaginglinkage member 3534 and is fixed thereto by clamping the plate 3562secured by mechanical fasteners. The other end of the strap is connectedto a hook 3564 suitable for grabbing a door handle. As the door-engaginglinkage member 3534 rotates in a closing direction, the strap and hookassembly pulls the door under test closed.

As shown in FIG. 48, a second door closing device 3570 is provided fordoors lacking convenient places for attaching the hook 3564. The seconddoor closing device 3570 comprises a pivotally mounted arm 3572 disposedon the door-engaging linkage member 3534. The pivotally mounted arm 3572is attached to the linkage member 3534 by conventional means. An aircylinder 3574 having an extensible piston also mounted to the doorengaging linkage member 3534 by conventional means is operativelyconnected to the pivotally mounted arm 3572. As the piston of the aircylinder 3574 is extended or retracted, the pivotally mounted arm 3572rotates into or out of engagement with the door under test.Specifically, as the piston of the air cylinder 3574 is extended, anL-shaped portion 3576 of the arm 3572 rotates into position behind theedge of the door under test. When the door-engaging linkage member 3534rotates in a closing direction, the L-shaped portion 3576 of the arm3572 pulls the door to closure. Once the door is fully closed, thepiston of the air cylinder 3574 retracts and thereby rotates the arm3572 out of engagement with the door under test.

Thus, a complete cycle of the 180-degree inside door actuator 3500 canbe described as follows. Assuming the door under test is initially in afully closed position, the door under test is first unlatched (anymechanism that can unlatch the door, including those described below,may be incorporated). Once the system receives confirmation that thedoor is unlatched, the motor 3504 begins rotating in an openingdirection (depending upon the relative position of the actuator 3500 tothe door under test, the direction of rotation may be counterclockwiseor clockwise). As stated above, the fixed sprocket 3512 and chain 3528remain fixed and do not rotate. By comparison, however, the electricmotor 3504 rotates the rotating plate 3514 in an opening direction. Suchrotation causes the freely rotating sprockets 3520 to roll along thefixed chain 3528 as described above. By virtue of their connection thefreely rotating sprockets 3520, the parallel linkage members 3532 rotateabout the axes of their associated sprocket. Additionally, since theplate 3514 to which the parallel members 3532 are connected orbits aboutthe motor axis, the parallel members 3532 also rotate about the motoraxis. Thus, with this configuration, the two isosceles triangles 3524,3542 formed by the linkage assembly 3502 rotate in parallel butdisplaced arcs. As described above, this configuration causes thedoor-engaging linkage member 3534 to follow an arc of rotation that iscoaxial with the door's rotation. The roller 3552 of the door-engaginglinkage assembly 3534 contacts the door under test at a single point andpushes the door in an opening direction as the rotating plate 3514 isrotated in an opening direction.

Thereafter, one of the door closing assemblies engages the door undertest as described above. The electric motor 3504 reverses and beginsrotating in a closing direction and the door under test is pulledclosed.

HORIZONTALLY HINGED ACTUATORS

Assisted hood actuator

As shown in FIG. 49, an assisted hood actuator 4100 is provided forcycling assisted hoods of vehicles under test that are biased orsupported in an open position by springs or cylinders. The assisted hoodactuator 4100 comprises generally a C-shaped lift arm 4102, a slammechanism 4104 for closing the hood, a lift hand assembly 4106 forlifting the hood, various supports and brackets, a driver 4108operatively engaged to the lift arm 4102, and dampers and bumpers. Moreparticularly, the assisted hood lift arm 4102 comprises two parallelmembers 4110, preferably constructed from stainless steel tubing, fixed,preferably by welding, to opposed ends of an intermediate member 4112,also preferably constructed from stainless steel tubing, constructed andarranged in a square C-shape. (See FIG. 50 for a more detailed view.)Preferably, a stiffener member 4114 is disposed, preferably at 45°, ineach of the corners of the C-shaped hood lift arm 4102. The hood liftarm 4102 is constructed to be wider than the width of a vehicle undertest.

The hood lift arm 4102 is mounted pivotally to a small 100, medium 300,or large 500 main frame for rotation about a horizontal axis such thatthe parallel members 4110 of the lift arm 4102 extend outwardly from themain frame 100, 300, 500. The following detailed description refersparticularly to the small mainframe 100, although it could have equallyreferred to the medium 300 or large 500 mainframes. In addition, thisdetailed description focuses primarily on the embodiment in which theassisted hood actuator 4100 is mounted to the front of the mainframe 100although another embodiment comprises the assisted hood actuator 4100mounted to the rear of the mainframe 100.

Specifically, a bearing plate mount 4116 comprising a first plate 4118having a plurality of holes therethrough arranged along each lateralside of the plate 4118 is provided for each side of the main frame 100.A rectangular steel tube 4120 is fixed, preferably by welding, to onesurface of the first plate 4118 and extends perpendicularly therefrom. Astiffener member 4122 is attached, preferably by welding between therectangular steel tube 4120 and the first plate 4118. A second plate4124 also having holes arranged in an identical pattern to the firstplate 4118 is also provided. The bearing plate mount 4116 is positionedin abutting relation to each vertical member 120, 122 of a main frame100 and is fixed thereto by mechanical fasteners which pass through theholes of the first 4118 and second 4124 plates. The bearing plate mounts4116 are fixed to the main frame such that the rectangular steel tubes4120 extend rearwardly.

Similarly, a bearing mount plate 4126 is provided for each bearing platemount 4116 and is adapted to be attached to the rectangular steel tube4120 of the bearing plate mount 4116. Specifically, the bearing mountplate 4126 defines two sets of holes. The first set is arranged in asquare configuration spaced sufficiently apart to be wider than thewidth of the rectangular steel tube 4120 of the bearing plate mount4116. The second set of holes is positioned laterally from the first setof holes and are configured to align with a conventional bearingassembly 4128. A second plate 4130 also having a set of holes positionedidentically as the first set of holes of the bearing mount plate 4126 isalso provided. A bearing mount plate 4126 is fixed to each of therectangular steel tubes 4120 of the bearing plate mounts 4116 such thatthe second set of holes are disposed above the rectangular steel tube4120 and is clamped in place by mechanical fasteners passing through theholes of the first 4126 and second 4130 plates. A bearing assembly 4128suitable for the expected loads and frequency of cycling is fixed toeach bearing mount plate 4126 at the second set of holes. A suitablebearing 4128 is the SEALMASTER Number FB-16T or equivalent. The bearingplate mount 4116, bearing mount plate 4126 and bearing assembly 4128 arepositioned on both vertical members 154, 156, or 120, 122 of either therearward 104 or forward 102 frame such that the bearings 4128 arecoaxial with the axis of rotation of the hood under test.

A check mount assembly 4132 comprising a plate 4124 having a pluralityof holes aligned along the lateral edges of the plate 4124 is attachedto each side 120, 122 of the main frame 100. Preferably, the holes ofthe plate 4124 are positioned identically to the mounting holes of thebearing plate mount 4118, and, thus, the plate is suitable forcooperation with the bearing plate mount 4116 to clamp both members tothe vertical member 120, 122 of the main frame 100. As is best viewed inFIG. 51, a second plate 4134 is fixed, preferably by welding,perpendicularly to the first plate 4124 and extends horizontallytherefrom. Preferably, a stiffener member 4136 is disposed between thefirst plate 4124 and the second plate 4134. The second plate 4134defines a pair of holes for mounting a damper 4138 and bumper 4140, asexplained in more detail below. As configured, the second plate 4134 ofthe check mount assembly 4132 is substantially parallel with the steeltube member 4120 of the bearing plate mount 411 G but extends in anopposite direction.

As discussed above, the hood lift arm 4102 is configured to pivothorizontally between the vertical members 154, 156 or 120, 122 of eitherthe rearward 104 or forward 102 frame. A cylindrical bracket 4142 andpin 4144 assembly is provided. The assembly comprises a cylindricalbracket 4142, similarly constructed and arranged as previously describedbrackets, and a pin 4144 fixed to the bracket 4142. Specifically, thecylindrical bracket 4142 has a bore adapted to clamp to the parallelmembers 4110 of the hood lift arm 4102. A bearing pin 4144 is fixed,preferably by welding, to the lateral surface of the cylindrical bracket4142 such that the axis of the bore of the bracket 4142 is perpendicularto the axis of the bearing pin 4144. A bracket and pin assembly isattached to each parallel member 4110 of the hood lift arm 4102 suchthat the pins 4144 are coaxial but extend outwardly. The pins 4144 areinserted into the bearings 4128.

An upper cylinder mount 4146 is fixed to each parallel member 4110 ofthe hood lift arm 4102 forward of the bearing assemblies 4128.Specifically, the upper cylinder mount 4146 comprises a cylindricalbracket 4147, as previously described with other modules, and a mountingplate 4148 fixed, preferably by welding, thereto. The mounting plate4148 defines a hole in the plate. The upper cylinder mount assembly 4146is fixed to the hood lift arm 4102 such that the mount plate 4148extends downwardly and the axis of the hole is positionedperpendicularly to the parallel members 4110 of the hood lift arm 4102.

The assisted hood lift actuator 4100 further comprises a lower cylindermount assembly 4150. Specifically, the assembly comprises a plate 4152having a plurality of holes, preferably arranged in a squareconfiguration, adapted for mounting on a vertical member 154, 156 or120, 122 of either the rearward 104 or forward 102 frame. The holes ofthe plate 4152 are spaced wider than the width of the vertical member120, 122 of the frame 102. A steel tube 4154 is fixed, preferably bywelding, to the plate 4152 and extends perpendicularly therefrom.Preferably, the steel tube 4154 is constructed from stainless steel. Asecond plate 4156 having a set of holes arranged identically to thefirst plate 4152 is also provided. The tube and plate assembly 4150 isfixed to a vertical member 154, 156 or 120, 122 of either the rearward104 or forward 102 frame by mechanical fasteners passing through alignedholes of the first 4152 and second 4156 plate. The plate and tubeassembly 4150 is fixed to the frame such that the tube 4154 extendsoutwardly from the main frame 100. A lower tube support 4158 comprisinga cylindrical bracket 4149, as described above, is configured to clampto the steel tube 4154 of the tube and plate assembly 4150. A threadedrod 4160 is fixed, preferably by welding, to a side of the cylindricalbracket 4149 such that the threaded rod 4160 extends perpendicularly tothe bore of the cylindrical bracket 4149. The threaded rod 4160 isattached to the horizontal member of the T-shaped support assembly 126and extends vertically therefrom such that the bore of the cylindricalbracket 4149 is coaxial with the tube 4154. The cylindrical bracket 4149is clamped to the tube 4154 thereby providing a second support for thetube 4154.

The lower cylinder support 4158 further comprises a pair of cylindricalbrackets 4149 welded together such that the bores of the brackets 4149are spaced angularly approximately 80°. (See FIG.49.) One of thebrackets 4149 of the pair is clamped to the tube 4154 of the tube andplate assembly 4150 such that the axis of the second bracket 4149inclines toward the main frame 100. Finally, a lower cylinder mount4162, adapted to be clamped within the cylindrical bracket 4149 andpreferably constructed from steel tube 4164, is clamped within thesecond cylindrical bracket 4149 of the pair of cylindrical brackets4149. Specifically, the lower cylinder mount 4162 comprises a plate 4166having a hole therethrough for mounting the other end of the driver4108. A steel tube 4164, preferably constructed from stainless steel, isfixed, preferably by welding, to the plate 4166 and is spaced laterallyfrom the hole. As configured, the tube 4164 of the lower cylinder mount4162 is clamped in the second cylindrical bracket 4149 of the pair ofbrackets 4149 such that the plate 4166 of the lower cylinder mount 4162is positioned below the horizontal tube 4154 of the tube and plateassembly 4150.

The slam mechanism 4104 for closing the hood is disposed on theintermediate segment 4112 of the hood lift arm 4102 and is adapted toclose the hood when the hood lift arm 4102 is rotated in a closingdirection. The lift hand assembly 4106 is also disposed on theintermediate member 4112 of the hood lift arm 4102 and is adapted tolift the hood when the hood lift arm 4102 is rotated in an openingdirection. More particularly, as shown in FIG. 49, the slam mechanism4104 comprises a roller 4168 rotatably mounted at an end of one arm of abell crank 4170. Any pliable roller 4168 suitable for contacting a hoodof a vehicle under test without imparting damage to the hood may beused. A FAIRLANE # DR-754-20 or equivalent is suitable for thisapplication. The bell crank 4170 having two arms angularly spaced ispivotally mounted to a bearing assembly 4172 at a point of intersectionbetween the two arms of the bell crank 4170. A suitable bearing assembly4172 is a TORRINGTON # KP-6 or equivalent. A cylindrical bracket 4173,as described above, is fixed to the bearing assembly 4172 such that theaxis of the bore of the bracket 4173 is parallel to the axis of rotationof the bell crank 4170. An air cylinder mounting plate 4174 is fixed tothe cylindrical bracket 4173. A driver 4176 having an extensible pistonor screw 4178, preferably an air cylinder, is mounted to the mountingplate 4174 such that the extensible piston 4178 is substantiallyparallel with the mounting plate 4174 and extended towards the secondarm of the bell crank 4170. The piston 4178 of the air cylinder 4176 ispivotally mounted to the end of the second arm of the bell crank 4170.

The slam mechanism 4104 is mounted to the hood lift arm 4102 such thatupon activation of the air cylinder 4176 the bell crank 4170 is rotatedtowards the hood and the roller 4168 engages a top surface of the hood.

The lift hand assembly 4106, which is best viewed in FIG. 52, comprisesa pair of cylindrical brackets 4179, as described above, alignedcoaxially and fixed, preferably by welding, to a mount plate 4180. Themount plate 4180 is fixed to a support plate 4182. A pair of linearbearings having shafts 4184 slidably mounted therein are disposed on thesupport plate 4182 such that the shafts 4184 are positioned parallel andspaced laterally from each other. A conventional coupler 4186 is mountedto the shafts 4184 such that the coupler 4186 is movable fore and aft asthe shafts 4184 slide within the linear bearing. A driver 4188 having anextensible piston, preferably an air cylinder, is mounted parallel andbetween the shafts 4184 of the linear bearings such that the piston ofthe cylinder 4188 extends parallel in the same direction as the shafts4184. The cylinder 4188 is mounted to a cylinder mount 4190 fixed to thesupport plate 4182. The end of the extensible piston is fixed to thecoupler 4186. A lift hand 4192 having a substantially L-shapedconfiguration providing a substantially horizontal surface 4194 parallelwith the mount 4180 and support 4182 plates is mounted to the oppositeside of the coupler 4186. A bumper 4196 is fixed to the surface of thelift plate 4194. Upon activation of the cylinder 4188, the lift plate4194 extends or retracts as required. A suitable cylinder 4188 isprovided by SMC # NCQ2B40-50. The lift hand assembly 4106 is fixed tothe lift hood arm 4102 such that the lift plate 4194 can extend towardsand engage the hood under test.

A bumper 4140 is fixed to the check mount 4132 and extends verticallyand upwardly to engage the hood lift arm 4102 in a fully closedposition. A suitable bumper 4140 is a McMASTER-CARR # 9732K15 orequivalent. A damper 4138 is mounted to the check mount 4132 and extendsvertically and upwardly to engage the hood lift arm 4102 in a fullyclosed position. A suitable damper 4138 is the ENIDINE 1.0B-03 orequivalent. Preferably, an electric cylinder 4108 having an extensiblepiston is mounted pivotally to the upper cylinder mount 4146 at the endof the piston and is mounted pivotally at the opposed end of thecylinder 4108 to the lower cylinder mount 4162. A suitable cylinder 4108is the # TH4104B-18-MP2-MT1 or equivalent.

An electric cylinder 4108 is preferred over other drivers to properlysimulate human closure of hoods. This configuration is particularlynecessary when the vehicle under test is cycled at extreme temperatures.While air cylinders may be used, they are subject to varied outputs asthe ambient temperature changes. To ensure proper simulation of thevelocity profile of a hood being closed by a human, an electricactuator--significantly less affected by temperature extremes--ispreferred.

Additionally, while the control system should slow the hood lift arm4102 down before the electric cylinder 4108 bottoms, the bumper 4140 anddamper 4138 provides additional protection to the actuator 4100. Thus,the bumper 4140 and damper 4138 should be positioned relative to thehood lift arm 4102 such that the hood lift arm 4102 engages the bumper4140 after a stroke of the actuator sufficient to rotate the arm 4102 toclose the hood has been applied but before the electric actuator 4108bottoms. Moreover, given that the assisted hood actuator 4100 can beused to slam the hood, the damper 4138 provides a device to dissipatethe energy of the moving hood lift arm 4102.

The assisted hood lift actuators 4100 are provided preferably in twosizes. A small hood lift actuator is adapted for use with hoods ofcompact vehicles. A large assisted hood actuator is adapted for use withlarger vehicles. Both hood lift actuators are constructed and arrangedidentically except that the relative dimensions are increased for thelarger actuator and the driver 4108 is sized for the larger loadsexpected from larger vehicle hoods.

The assisted hood actuator 4100 is operated as follows. A hood of avehicle under test is unlatched prior to activation of the actuator4100. Initially, the lift plate 4194 of the lift hand assembly 4106 isextended towards the released hood such that it engages an edge of thehood. The cylinder 4188 extends the lift plate 4194. Once the lift platehas engaged the hood, the cylinder 4108 is activated to rotate the arm4110 in an opening direction. Once the hood has reached a full-openposition, further extension of the piston of the cylinder 4108 isstopped.

Thereafter, the roller 4168 is rotated into engagement with the hood asthe piston 4178 of the cylinder 4178 is extended. Specifically, as thepiston 4178 extends, the crank 4170 is rotated until the roller 4168engages the hood under test. Next, the lift plate 4194 is retracted outof engagement with the hood. Once positioned, the cylinder 4108 retractsits piston to rotate the arm 4110 in a closing direction. The cylinderpiston is retracted at a rate that will simulate human door closure. Byvirtue of the roller's 4168 contact with the door under test, therotation of the arm 4110 will close the hood. Over-rotation of the armis prevented by proper control of the cylinder 4108. Additionally, thebumper 4140 prevents over-rotation. The damper 4138 dampens any shockloading associated with any impact by the arm 4110 against the bumper4140.

Free-fall hood actuator

As shown in FIG. 54, a free-fall hood actuator 4300 is provided forcycling free-fall hoods of vehicles under test that remain in an openposition only when supported by prop rods. The free-fall hood actuator4300 comprises generally a C-shaped lift arm 4302, a lift hand assembly4304 for lifting and releasing the hood, various supports and brackets,a driver 4306 operatively engaged to the lift arm 4302, and dampers andbumpers. More particularly, the free-fall hood lift arm 4302 comprisestwo parallel members 4308, preferably constructed from stainless steeltubing, fixed, preferably by welding, to opposed ends of an intermediatemember 4310, also preferably constructed from stainless steel tubing,constructed and arranged in a square C-shape. (See FIG. 55.) Preferably,a stiffener member 4312 is disposed, preferably at 45°, in each of thecorners of the C-shaped hood lift arm 4302. The hood lift arm 4302 isconstructed to be wider than the width of a vehicle under test.

The hood lift arm 4302 is mounted pivotally to a small 100, medium 300,or large 500 main frame for rotation about a horizontal axis such thatthe parallel members 4308 of the lift arm 4302 extend outwardly from themain frame 100, 300, 500. The following detailed description refersparticularly to the small mainframe 100, although it could have equallyreferred to the medium 300 or large 500 mainframes. In addition, thisdetailed description focuses primarily on the embodiment in which thefree-fall hood actuator 4300 is mounted to the front of the mainframe100 although another embodiment comprises the free-fall hood actuator4300 mounted to the rear of the mainframe 100.

Specifically, a bearing plate mount 4314 comprising a first plate 4316having a plurality of holes therethrough arranged along each lateralside of the plate 4316 is provided for each side 120, 122 of the mainframe 100. The rectangular steel tube 4318 is fixed, preferably bywelding, to one surface of the first plate 4316 and extendsperpendicularly therefrom. A stiffener member 4320 is attached,preferably by welding, between the rectangular steel tube 4318 and thefirst plate 4316. A second plate 4322 also having holes arranged in anidentical pattern to the first plate 4316 is also provided. The bearingplate mount 4314 is positioned in abutting relation to each verticalmember 120, 122 of a main frame 100 and is fixed thereto by mechanicalfasteners which pass through the holes of the first plate 4316 andsecond plate 4322. The bearing plate mounts 4314 are fixed to the mainframe 100 such that the rectangular steel tubes 4318 extend rearwardlyfrom the forward frame member.

Similarly, a bearing mount plate 4324 is provided for each bearing platemount 4314 and is adapted to be attached to the rectangular steel tube4318 of the bearing plate mount 4314. Specifically, the bearing mountplate 4324 defines two sets of holes. The first set is arranged in asquare configuration spaced sufficiently apart to be wider than thewidth of the rectangular steel tube 4318 of the bearing plate mount4314. The second set of holes is positioned laterally from the first setof holes and are configured to align with a conventional bearingassembly 4326. A second plate 4328 also having a set of holes positionedidentically as the first set of holes of the bearing mount plate 4324 isalso provided and is positioned on the opposed surfaces of the tube 4318such that all holes align. A bearing mount plate 4324 is fixed to eachof the rectangular steel tubes 4318 of the bearing plate mounts 4314such that the second set of holes are disposed laterally from therectangular steel tube 4318 and is clamped in place by mechanicalfasteners passing through the holes of the first plate 4324 and secondplate 4328. A bearing assembly 4326 suitable for the expected loads andfrequency of cycling is fixed to each bearing mount plate 4324 at thesecond set of holes. Each of the parallel members 4308 is mountedpivotally to the bearing assemblies 4326. A suitable bearing 4326 is theMB # MFB-25K-1 or equivalent. A bearing plate mount 4314, bearing mountplate 4324 and bearing assembly 4326 is positioned on both verticalmembers 154, 156, or 120, 122 of either the rearward 104 or forward 102frame such that the bearings 4126 are coaxial with the axis of rotationof the hood under test.

A check mount assembly 4330 comprising the plate 4322 having a pluralityof holes aligned along the lateral edges of the plate 4322 is attachedto each side of the main frame 100. Preferably, the holes of the plate4322 are positioned identically to the mounting holes of the bearingplate mount 4314, and, thus, the plate 4322 is suitable for cooperationwith the bearing plate mount 4314 to clamp both members to the verticalmember 120, 122 of the main frame 100. A second plate 4332 is fixed,preferably by welding, perpendicularly to the first plate 4322 andextends horizontally therefrom. Preferably, a stiffener member 4334 isdisposed between the first plate 4322 and the second plate 4332. Thesecond plate 4332 defines a pair of holes for mounting a damper 4336 anda bumper 4338, as explained in more detail below. As configured, thesecond plate 4332 of the check mount assembly 4330 is substantiallyparallel with the steel tube member 4318 of the bearing plate mount 4314but extends in an opposite direction.

As discussed above, the hood lift arm 4302 is configured to pivothorizontally between the vertical members of either the rearward frame104 or forward frame 102. A cylindrical bracket 4340 and pin 4342assembly is provided. The assembly comprises a cylindrical bracket 4340,similarly constructed and arranged as previously described cylindricalbrackets, and a pin 4342 fixed to the bracket 4340. Specifically, thecylindrical bracket 4340 has a bore adapted to clamp to the parallelmembers 4308 of the hood lift arm 4302. A bearing pin 4342 is fixed,preferably by welding, to the lateral surface of the cylindrical bracket4340 such that the axis of the bore of the bracket 4340 is perpendicularto the axis of the bearing pin 4342. A bracket and pin assembly isattached to each parallel member 4308 of the hood lift arm 4302 suchthat the pins 4342 are coaxial but extend outwardly. The pins 4342 areinserted into the bearings 4326.

An upper cylinder mount 4344 is fixed to each parallel member 4308 ofthe hood lift arm 4302 forward of the bearing assemblies 4326.Specifically, the upper cylinder mount 4344 comprises a cylindricalbracket 4345, as previously described with other modules, and a mountingplate 4346 fixed, preferably by welding, thereto. The mounting plate4346 defines a hole in the free end of the plate. The upper cylindermount assembly 4344 is fixed to the hood lift arm 4302 such that themount plate 4346 extends downwardly and the axis of the hole ispositioned perpendicularly to the parallel members 4308 of the hood liftarm 4302.

The free-fall hood lift actuator 4300 further comprises a lower cylindermount assembly 4348. Specifically, the assembly 4348 comprises a plate4350 having a plurality of holes, preferably arranged in a squareconfiguration, adapted for mounting on a vertical member of either therearward frame 104 or forward frame 102. The holes of the plate 4350 arespaced wider than the width of the vertical member 120, 122 of the frame102. A tube 4352 is fixed, preferably by welding, to the plate 4350 andextends perpendicularly therefrom. A stiffener member 4354 is attached,preferably by welding, between the plate 4350 and the tube 4352.Preferably, the tube 4352 is constructed from stainless steel. A secondplate 4356 having a set of holes arranged identically to the first plate4350 is also provided. The tube and plate assembly 4348 is fixed to avertical member of either the rearward frame 104 or forward frame 102 bymechanical fasteners passing through aligned holes of the first plate4350 and second plate 4356. The plate and tube assembly 4348 is fixed tothe frame 120, 122 such that the tube 4352 extends outwardly from themain frame 100. The lower cylinder mount assembly 4348 further comprisesa pair of cylindrical brackets 4349 welded together such that the boresof the brackets 4349 are spaced angularly approximately 80°. Thebrackets 4349 are constructed and arranged as previously described. Oneof the brackets 4349 of the pair is clamped to the tube 4352 of the tubeand plate assembly 4348 such that the axis of the second bracket 4349inclines toward the main frame 100. Finally, a lower cylinder mount4358, adapted to be clamped within the cylindrical bracket 4349 andpreferably constructed from steel tube, is clamped within the secondcylindrical bracket 4349 of the pair of cylindrical brackets 4349.Specifically, the lower cylinder mount 4358 comprises a plate 4362having a hole therethrough for mounting to the other end of the driver4306. A steel tube 4360, preferably constructed from stainless steel, isfixed, preferably by welding, to the plate 4362 and is spaced laterallyfrom the hole. As configured, the tube 4360 of the lower cylinder mount4358 is clamped in the second cylindrical bracket 4349 of the pair ofbrackets 4349 such that the plate 4362 of the lower cylinder mount 4358is positioned laterally from the horizontal tube 4352 of the tube andplate assembly 4348.

As shown in FIG. 54, a lift hand assembly 4304 is fixed to theintermediate member 4310. The lift hand assembly 4304 comprises a pairof cylindrical brackets 4364, constructed and arranged as describedabove, aligned coaxially and fixed, preferably by welding, to a mountplate 4366. The mount plate 4366 is fixed to a support plate 4368. Apair of linear bearings having shafts 4370 slidably mounted therein aredisposed on the support plate 4368 such that the shafts 4370 arepositioned parallel and spaced laterally from each other. A conventionalcoupler 4372 is mounted to the shafts 4370 such that the coupler 4372 ismovable fore and aft as the shafts 4370 slide within the linearbearings. A driver 4374 having an extensible piston, preferably an aircylinder, is mounted parallel and between the shafts 4370 of the linearbearings such that the piston of the cylinder 4374 extends parallel inthe same direction as the shafts 4370. The cylinder is mounted to acylinder mount 4376 fixed to the support plate 4368. The end of theextensible piston is fixed to the coupler 4372. A lift hand 4378 havinga substantially L-shaped configuration providing a substantiallyhorizontal surface 4380 parallel with the mount 4366 and support 4368plates is mounted to the opposite side of the coupler 4372. A bumper4382 is fixed to the surface of the lift plate 4380. Upon activation ofthe cylinder 4374, the lift plate 4380 extends or retracts as required.A suitable cylinder 4374 is a SMC # NCQ2B40-50 or equivalent. The lifthand assembly 4304 is fixed to the lift hood arm 4302 such that the liftplate 4380 can extend towards and engage the hood under test.

A bumper 4338 is fixed to the check mount 4330 and extends verticallyand upwardly to engage the hood lift arm 4302 in a fully closedposition. A suitable bumper 4338 is a McMASTER-CARR # 9732K15 orequivalent. A damper 4336 is mounted to the check mount 4330 and extendsvertically and upwardly to engage the hood lift arm 4302 in a fullyclosed position. A suitable damper 4336 is the ENIDINE 1.0B-03 orequivalent.

The driver 4306, preferably an electric cylinder, having an extensiblepiston is mounted pivotally to the upper cylinder mount 4344 at the endof the piston and is mounted pivotally at the opposed end of thecylinder 4306 to the lower cylinder mount 4358. A suitable cylinder 4306is the SMC NCA1R250 or equivalent. More particularly, a stop cylinderabutment 4384 is fixed to the end of the extensible piston of theelectric cylinder 4306. The abutment 4384, which is most easily viewedin FIG. 56, comprises a plate 4386 and a member 4388 defining a holetherethrough extending perpendicularly therefrom. As configured, theplate 4386 extends perpendicularly to the piston of the electriccylinder 4306 past the width of the cylinder 4306.

An electric cylinder 4306 is preferred over other drivers to properlysimulate human closure of hoods. This configuration is particularlynecessary when the vehicle under test is cycled at extreme temperatures.While air cylinders may be used, they are subject to varied outputs asthe ambient temperature changes. To ensure proper simulation of avelocity profile of a hood being closed by a human, an electricactuator--significantly less affected by temperature extremes--ispreferred.

The free-fall hood actuator 4300 also includes the bumper 4338 and thedamper 4336 constructed and arranged substantially identically as in theassisted hood actuator 4100. Because a free-fall hood is dropped toclosure rather than actively pushed to closure, however, there isgenerally less lift arm energy to dissipate by the damper 4336.Consequently, the bumper 4338 and damper 4336 plays a more importantrole in the assisted hood actuator 4100.

The free-fall hood actuator 4300, however, also comprises preferably astop cylinder assembly 4390. A stop cylinder mount plate 4392, which canalso be seen in FIG. 57, is fixed, preferably by mechanical fasteners,to the lift arm actuator 4306 and provides a mounting surface spacedlaterally from the lift arm cylinder 4306. A stop cylinder 4394 havingan extensible piston is fixed to the mount plate 4392 such that the stopcylinder 4394 is substantially parallel with the lift arm cylinder 4306and such that the stop cylinder piston extends in the same direction asthe piston of the lift arm cylinder 4306. A suitable stop cylinder 4394is a SMC NCA1R250 or equivalent.

Once the lift arm 4302 and lift hand assembly 4304 have lifted thefree-fall hood under test to its full open position, the stop cylinder4394 extends its piston to a desired drop height. Thereafter, the liftarm cylinder 4306 rotates the lift arm 4302 and lift hand 4304 in aclosing direction until the stop cylinder abutment 4384 engages the endof the extended piston of the stop cylinder 4394. Thus, the stopcylinder abutment 4384 must be positioned across the longitudinal axisof the stop cylinder 4394, and the extension of the stop cylinder 4394must be sufficiently long to cover all expected drop heights, asdescribed below. The stop cylinder 4394 is extended to a predeterminedlength that sets the drop height of the hood under test to apredetermined value. In other words, the lift arm 4302 can only rotatein a closing direction until the stop cylinder abutment 4384 engages thepiston of the stop cylinder 4394 thereby preventing further rotation ofthe arm 4302 and positioning the arm 4302 at some height above fullclosure. At the predetermined height, the lift hand 4304 is retractedand the hood under test is allowed to free fall through thepredetermined height.

The stop cylinder 4394 provides the preferred method of setting the hooddrop height. Sensors or limit switches, for example, could be used toindicate drop height and initiate free fall. Such a process, however,would not provide accurate control over drop height at temperatureextremes. As the lift arm 4302 rotated the hood under test towardsclosure, the lift hand 4378, retracted by an air cylinder 4374, wouldrespond in times that varied with temperature thereby varying the dropheight. For example, if the lift hand 4378 took longer to fullyretract--because of a temperature variation--following free-fallinitiation while the lift arm 4302 was rotated, the drop height would belowered. Thus, it would be difficult to release the hood under test atthe same drop height for tests at different temperature extremes.

The free-fall hood lift actuator 4300 is provided preferably in twosizes. A small hood lift actuator is adapted for use with hoods ofcompact vehicles. A large free-fall hood actuator is adapted for usewith larger vehicles. Both hood lift actuators are constructed andarranged identically except that the relative dimensions are increasedfor the larger actuator and the driver 4306 is sized for the largerloads expected from larger vehicle hoods.

Decklid release

A decklid release 4500 cycles a rear lid locking mechanism of any truck,automobile or van by simulating the unlocking action when a key isinserted into the lid's locking mechanism and turns. The decklid can bea car trunk, hatch back, van door, station wagon door, rear truck dooror any other like decklid horizontally disposed on a vehicle. Generally,as shown in FIG. 58, the decklid release 4500 comprises a supportassembly 4501, an actuation assembly 4508, and a head assembly 4524.

The support assembly 4501 comprising a support arm 4502 disposedsubstantially horizontally is attached to a transverse member clamp 4503and supports a cylinder mount 4509, a pivot mount 4510, and a levellingmount 4506. More particularly the transverse member clamp 4503 attachesthe support assembly 4501 substantially perpendicularly from thetransverse member 158 of the rear frame 104 so that the support assembly4501 extends rearwardly from the main frame. The transverse member clamp4503 comprises two parallel plates positioned about the transversemember 158 and is clamped to the transverse member 158 by any suitablemeans. One of the plates is fixed to an end of the support arm 4502,preferably by welding, such that the plate's face is substantiallyperpendicular to a longitudinal axis of the support arm 4502.Preferably, the plates are secured to the main frame by mechanicalfasteners that pass through the plate attached to the support arm 4502and tighten upon the plate opposed to the first plate, thereby clampingthe support arm 4502 to the main frame. Consequently, the fasteners canbe loosened such that the decklid release 4500 can be positionedanywhere along the width of the main frame.

Located at the opposite end of the support arm 4502, the levelling mount4506 is attached to the support arm 4502 by any suitable means.Preferably, a drill hole is disposed in the bottom side of the supportarm 4502. A levelling mount stem 4507 passes through the hole andsupports the arm 4502 when the levelling mount 4506 abuts the ground.Two fasteners disposed on the stem 4507 are positioned on opposite sidesof a support arm wall. Each of the fasteners can be tightened againstthe arm 4502 thereby fixing the levelling mount 4506 to the support arm4502. A height of the levelling mount 4506, and consequently, thevertical position of the arm 4502, is adjusted to keep the decklidrelease 4500 level with the main frame.

Disposed between the transverse member clamp 4503 and the levellingmount 4506, the actuation assembly 4508 is attached to the support arm4502 by the cylinder mount 4509 and the pivot mount 4510. The cylindermount 4509 comprises a pair of plates 4504 substantially parallel to andabutting the arm 4502. The plates 4504 are clamped to the support arm4502 by any suitable means. Preferably, the plates 4504 are secured tothe support arm 4502 with mechanical fasteners that pass through theplates 4504 and tighten thereon, thereby securing the cylinder mount4509 to the support arm 4502. Consequently, the fasteners can beloosened such that the cylinder mount 4509 can be positioned anywherealong the length of the support arm 4502. A substantially verticalmember is attached at the end to the upper plate 4504, preferably bywelding, and includes a flange 4511 fixed at the opposed end thatextends laterally and perpendicularly from the vertical member. Anactuator mount 4512 is attached to the flange 4511 and provides anoffset pivot for an actuator 4513 as described below, positionedlaterally from the support arm 4502.

The pivot mount 4510 comprises two parallel plates 4505 positioned aboutand clamped to the support arm 4502 by any suitable means, preferably inthe manner described for the cylinder mount 4509. The pivot mount 4510also provides an offset pivot for a shaft 4523, as described below,positioned laterally from the support arm 4502. Consequently, as bestseen in FIG. 60, the offset cylinder mount 4509 and the offset pivotmount 4510 prevent interference between the shaft 4523 and the supportarm 4502.

An actuation cylinder 4513 having an extendable piston 4515 is mountedpivotally to the actuator mount 4512 by any suitable means such that thecylinder 4513 is offset yet substantially parallel to the support arm4502 when the shaft 4523 is substantially perpendicular to the supportarm 4502. One skilled in the art will recognize that any suitableactuator, including hydraulic and electric actuators, may beincorporated as the actuation cylinder 4513. Fixed to the opposite endof the actuation cylinder 4513 is a shock mount plate 4514. A centrallylocated hole is disposed in the lower part of the plate 4514 throughwhich the actuator piston 4515 can pass. A clamp 4518, preferably acollar, is mounted pivotally to the free end of the extendible piston4515 and is secured by any conventional means to the shaft 4523.

Intermediate to the cylinder 4513 and the clamp 4518, a shock striker4516 is fixed to the piston 4515. The shock striker 4516 provides ashock mounting surface 4517 that is substantially perpendicular to thepiston 4515.

A damper 4519 of any general variety is attached to the upper part ofthe shock mount plate 4514 such that the damper 4519 is located aboveand parallel to the actuation cylinder 4513. A suitable damper is theENIDINE damper #DEM 1.0B-04 or equivalent. One skilled in the art willrecognize that the damper 4519 may be located below and parallel to theactuation cylinder 4513 as well. A centrally located hole is disposed inthe upper part of the plate 4514 through which a piston 4520 of thedamper 4519 can pass. The free end of the piston 4520 abuts the shockmounting surface 4517 of the shock striker 4516 when the shaft 4523 isin the vertical configuration.

The shaft 4523 is attached to the piston mount 4510 with a pivot collar4521 which comprises two semi-circular members defining a boretherethrough when connected. One semi-circular member is fixed,preferably by welding, to a pivot flange 4522. The semi-circular membersseparate and can be positioned around and clamped to the vertical shaft4523 by any suitable means. Specifically, the free semi-circular memberincorporates screws that pass through the free semi-circular member andtighten into threads tapped into the semi-circular member fixed to theflange 4522, thereby securing the flange 4522 to the shaft 4523. Theflange 4522 extends parallel to the longitudinal direction of thesupport arm 4502 and is secured to the pivot mount 4510 by any suitablemeans such that the pivot collar 4521, and consequently the shaft 4523,can freely rotate about the axis defined perpendicularly to the pivotmount fastener. As previously described, the clamp 4518 is fixed to theshaft 4523 such that upon activation of the cylinder 4513, the shaft4523 is rotated about the mount 4510.

One skilled in the art will recognize that the actuation cylinder 4513can be disposed between the vertical shaft 4523 and the levelling mount4506. One skilled in the art will also recognize that the cylinder mount4509 and pivot mount 4510 can be offset laterally to either side of thesupport arm 4502.

As shown in FIGS. 62 and 63, the head assembly 4524 comprises a cylinderfloater assembly 4525 that is secured to the vertical shaft 4523 by acylindrical bracket 4526 that can be positioned about and clamped to theshaft 4523 by any suitable means. The bracket 4526, constructed as thepreviously described cylindrical brackets, is incorporated as part of abumper mount 4527 that extends substantially perpendicularly from thevertical shaft 4523. A bumper standoff 4528, having a bumper 4529secured thereto, is attached to the free end of the bumper mount 4527 byany suitable means. A biasing element 4537, preferably a compressiblespring, is fixed to the standoff 4528 and extends past the bumper 4529.The free end of the biasing element 4537 abuts a cylinder assembly 4535and supports the weight of the cylinder assembly 4535, as describedbelow, without fully compressing the element 4537.

Disposed above the cylinder floater assembly 4525 and connected to theshaft 4523, a bearing assembly 4530, comprises a bearing mount 4531 anda linear bearing 4532 attached thereto. As shown in FIG. 62, the bearingmount 4531 comprises two cylindrical brackets 4533 fixed, preferably bywelding to either end of a bearing surface 4534 such that the brackets4533 are substantially perpendicular to the bearing surface 4534. Thebrackets 4533 are constructed as the previously described brackets andcan be positioned about and clamped to the shaft 4523 by any suitablemeans, thereby securing the bearing assembly 4530 to the shaft 4523.

The linear bearing 4532 is fastened to the bearing surface 4534 by anysuitable means such that the bearing 4532 provides linear motionparallel to the longitudinal axis of the shaft 4523. Specifically, thelinear bearing 4532 incorporates screws that pass through the bearing4532 and tighten upon threads tapped into the bearing surface 4534. Asuitable linear bearing is the THK bearing #HRV21 CA1 UU+0180 orequivalent.

The cylinder assembly 4535 is attached to the linear bearing 4532 suchthat the assembly 4535 moves linearly and substantially parallel to theshaft 4523. As previously described, extending from the bumper standoff4528 to the bottom of a cylinder mount block 4536 is the biasing element4537. The stiffness of the element 4537 is such that the element 4537can adequately support the weight of the cylinder assembly 4535 withoutbeing fully compressed. More particularly, the stiffness of the element4537 is selected to provide a spring force equal to the weight of thecylinder assembly 4535 that biases the cylinder assembly 4535 along itstravel on the bearing 4532. As configured, the element 4537 prevents thecylinder assembly 4535 from loading a decklid under test when thedecklid opens. Thus, the cylinder assembly 4535 "floats" along thebearing 4532 thereby keeping the cylinder assembly 4535 in the sameposition relative to the decklid under test as the decklid opens.

A cylinder mount plate 4538 fastens to the linear bearing 4532 by anysuitable means. Specifically, the cylinder mount plate 4538 incorporatesscrews that pass through the plate 4538 and tighten upon threads tappedinto the linear bearing 4532, thereby fixing the mount plate 4538 to thelinear bearing 4532. The cylinder mount block 4536 and a lift arm mount4539 are fixed to the cylinder mount plate 4538 by any suitable means.Specifically, the lift arm mount 4539 incorporates screws the passthrough the arm mount 4539 and the cylinder mount block 4536 and tightenupon threads tapped into the cylinder mount plate 4538, thereby securingthe lift arm mount 4539 and the cylinder mount block 4536 to the mountplate 4538.

An actuator 4545 having both an extendible and rotary piston is fixed tothe cylinder mount block 4536 by any conventional means. One skilled inthe art will recognize that any suitable actuator, providing both linearand rotary activation, may be incorporated in this part of the decklidrelease 4500. Fixed to the free end of the piston of the actuator 4545by any conventional means is a key carriage 4550. A plunger 4548 isdisposed within the key carriage 4550 and can slide relative to thecarriage 4550. As configured, the actuator 4545 performs two operations.The first actuation is linear and substantially perpendicular to theshaft 4523. With this motion, the carriage 4550 can engage a key (notshown) previously inserted into a decklid locking mechanism.Alternatively, the carriage 4550 can insert a key into the lockingmechanism. The second actuation is rotational and about the longitudinalaxis of the actuator 4545. With this motion, the carriage 4550 acts toturn the decklid key and unlock the decklid locking mechanism, therebyreleasing the decklid. In any embodiment, the plunger 4548 ensures thatthe key is inserted fully into the lock.

As shown in FIG. 62, the lift arm mount 4539 comprises two cylindricalbrackets 4540 fixed, preferably by welding, to a base of the mount 4539such that the brackets 4540 are substantially perpendicular to the base.The cylindrical brackets 4540 are constructed as the previouslydescribed cylindrical brackets and can be positioned about and clampedto a lift arm 4541 by any suitable means, thereby securing the arm 4541to the lift arm mount 4539.

Finally, a roller mount shaft 4542, having a soft roller 4543 disposedat the end of the shaft 4542, is secured to the lift arm 4541 by a liftarm angle mount 4544. The roller mount shaft 4542 is oriented such thatthe soft roller 4543 extends diagonally away from the actuator 4545 atan angle, approximately 45 degrees. The lift arm angle mount 4544comprises two collars fixed to each other, preferably by welding, suchthat the axes of the collars are disposed relative to each other at thedesired angle. The collars are constructed as the previously describedcylindrical brackets and can be positioned about and clamped to the liftarm 4541 and roller mount shaft 4542 by any suitable means. The softroller 4543 is rotatably mounted onto the extended end of the rollermount shaft 4542 by any conventional means.

A bumper arm 4546 is fixed to the extended part of the roller mountshaft 4542, preferably by welding, such that the arm 4546 extendsdownwardly, away from the roller mount, such that the arm 4546 issubstantially parallel to the shaft 4541. A bumper 4547 is fixed by anyconventional means to the end of the arm 4546 such that the bumper 4547extends perpendicularly from the arm 4546.

Decklid actuator

As shown in FIG. 64, a decklid actuator 4700 is provided for cyclingdecklids of vehicles under test. Prior to cycling of the decklid, thedecklids are released, preferably by the decklid release device 4500described above. The decklid actuator 4700 comprises generally aC-shaped lift arm 4702, a slam mechanism 4704 for closing the decklid, alift hand assembly 4706 for lifting the decklid, various supports andbrackets, a driver 4708 operatively engaged to the lift arm 4702, anddampers and bumpers. More particularly, as best viewed in FIG. 65, thedecklid lift arm 4702 comprises two parallel members 4710, preferablyconstructed from stainless steel tubing, fixed, preferably by welding,to opposed ends of an intermediate member 4712, also preferablyconstructed from stainless steel tubing, constructed and arranged in asquare C-shape. Preferably, a stiffener member 4714 is disposed,preferably at 45°, in each of the corners of the C-shaped decklid liftarm 4702. The decklid lift arm 4702 is constructed to be wider than thewidth of a vehicle under test.

The decklid lift arm 4702 is mounted pivotally to a small 100, medium300, or large 500 main frame for rotation about a horizontal axis suchthat the parallel members 4710 of the lift arm 4702 extend outwardlyfrom the main frame 100, 300, or 500. The following detailed descriptionrefers particularly to the small mainframe 100, although it could haveequally referred to the medium 300 or large 500 mainframes. In addition,this detailed description focuses primarily on the embodiment in whichthe decklid actuator 4700 is mounted to the rear of the main frame 100although another embodiment comprises the decklid actuator 4700 mountedto the front of the main frame 100.

Specifically, as shown in FIG. 69, a bearing plate support 4716comprising a first plate 4718 having a plurality of holes therethrougharranged along each lateral side of the plate 4718 is provided for eachvertical member 154, 156, of the rear frame member 104 of the main frame100. A first rectangular steel tube 4720 is fixed, preferably bywelding, to one surface of the first plate 4718 and extendsperpendicularly therefrom.

A shock mount support 4722 comprising a second plate 4724 having aplurality of holes arranged in an identical pattern to the plurality ofholes of the first plate 4718 is provided for each vertical member 154,156 of the rear frame member 104 of the main frame 100. A secondrectangular steel tube 4726 is fixed, preferably by welding, to onesurface of the second plate 4724 and extends perpendicularly therefrom.The bearing plate support 4716 and the shock mount support 4722 arepositioned in abutting relation to each vertical member 154, 156 of amain frame 100 such that the first rectangular steel tube 4720 extendsin a substantially longitudinal forward direction and the secondrectangular steel tube 4726 extends in a substantially longitudinalrearward direction. Preferably, the first bearing plate support 4716 andfirst shock mount support 4722 are each fixed to vertical member 154such that the longitudinal axis of the forward bearing plate support4716 is substantially coaxial with the longitudinal axis of the rearwardshock mount support 4722. Similarly, a second bearing plate support 4716and a second shock mount support 4722 are each fixed to vertical member156 such that the longitudinal axis of the second bearing plate support4716 is substantially coaxial with the longitudinal axis of the secondshock mount support 4722. The longitudinal axes of the two bearing platesupports 4716 and the two shock mount supports 4722 are substantially ina plane parallel to the plane of the bearing surface 112, as can be seenin FIG. 69.

More specifically, the bearing plate supports 4716 and the shock mountsupports 4722 are fixed to vertical members 154, 156 by aligning eachhole in plate 4718 with a corresponding hole in plate 4724 and attachinga mechanical fastener therethrough for each hole. Preferably, there arefour holes in each plate 4718, 4724 arranged to define the corners of asquare configuration which is wider than the rectangular steel tubes4720, 4726, 154, 156, and arranged such that there are two mechanicalfasteners attached along each lateral side of each mainframe member 154,156.

A bearing mount plate 4728 is provided for each bearing plate support4716 and is adapted to be attached to the rectangular steel tube 4720 ofthe bearing plate support 4716. Specifically, the bearing mount plate4728 defines two sets of holes. The first set is arranged in a squareconfiguration spaced sufficiently apart to be wider than the width ofthe rectangular steel tube 4720 of the bearing plate support 4716. Thesecond set of holes is positioned laterally from the first set of holesand are configured to align with a conventional bearing assembly 4730.As best viewed in FIG. 69, a second plate 4732 also having a set ofholes positioned identically as the first set of holes of the bearingmount plate 4728 is also provided. A bearing mount plate 4728 is fixedto each of the rectangular steel tubes 4720 of the bearing platesupports 4716 such that the second set of holes are preferably disposedbelow the rectangular steel tube 4720 and is clamped in place bymechanical fasteners passing through the holes of the first plate 4728and second plate 4732. A bearing assembly 4730 suitable for the expectedloads and frequency of cycling is fixed to each bearing mount plate 4728at the second set of holes. A suitable bearing is the SEALMASTER NumberFB-16T or equivalent. The bearing plate support 4716, bearing mountplate 4728 and bearing assembly 4730 is positioned on both verticalmembers 154, 156 of the rearward frame 104 such that the bearings arecoaxial with the axis of rotation of the decklid under test.

A shock mount assembly 4734 comprising a shock mount post 4736, a shockmount 4738, a bumper mount 4740, a damper 4742, and a bumper 4744 isprovided. As is best viewed in FIG. 66, the shock mount post 4736comprises a first plate 4746, with a plurality of holes therethrougharranged along each lateral side of the plate, and a tube 4748,preferably stainless steel, fixed perpendicularly to one surface of theplate 4746, preferably by welding. Two stiffener members 4750 areattached, preferably by welding, between the plate 4746 and the tube4748. A second unattached plate 4752 having a plurality of holesalignable with the holes of the first plate 4746 is provided. The shockmount post 4736 is attached in abutting relationship to the rectangulartube 4726 of the shock mount support 4722 such that the first plate 4746abuts the lower surface of the rectangular tube 4726, the shock mountpost tubing 4748 extends in a downward direction substantiallyperpendicular to the lower surface of the rectangular tube 4726, and thesecond unattached plate 4752 abuts the upper surface of the rectangulartube 4726 such that the plurality of holes align with the plurality ofholes in the first plate 4746. The first plate 4746 and second plate4752 are preferably wider than the rectangular tube 4726 such thatmechanical fasteners can be attached through the aligned holes on eachtransverse side of the tube 4726.

The shock mount 4738, shown in more detail in FIG. 68, comprises acollar clamp 4754 attached, preferably by welding, do a plate 4756 whichdefines a pair of holes for mounting the damper 4742 and the bumper4744, as explained in more detail below. A stiffening member 4758 ispreferably attached between the collar clamp 4754 and the plate 4756.The shock mount 4738 is selectively attached to the shock mount post4736 such that the plate 4756 is substantially parallel to the lowersurface of the rectangular steel tube 4726 of the shock mount support4722.

As discussed above, the decklid lift arm 4702 is configured to pivothorizontally between the vertical members of either the rearward frame154, 156 or forward frame 120, 122. As shown in FIG. 70, cylindricalbracket 4760 and pin 4762 assembly is provided. The assembly comprises acylindrical bracket 4760, similarly constructed and arranged aspreviously described cylindrical brackets, and a pin 4762 fixed to thebracket. Specifically, the cylindrical bracket 4760 has a bore adaptedto clamp to the parallel members 4710 of the decklid lift arm 4702. Abearing pin 4762 is fixed, preferably by welding, to the lateral surfaceof the cylindrical bracket 4760 such that the axis of the bore of thebracket 4760 is perpendicular to the axis of the bearing pin 4762. Thebracket 4760 and pin 4762 assembly is attached to each parallel member1410 of the decklid lift arm such that the pins 4762 are coaxial butextend outwardly. The pins 4762 are inserted into the bearings 4730.

An upper cylinder mount 4764 is fixed to each parallel member 4710 ofthe decklid lift arm 4702 forward of the bearing assemblies 4730.Specifically, the upper cylinder mount 4764 comprises a cylindricalbracket 4765, as previously described with other modules, and a mountingplate 4766 fixed, preferably by welding, thereto. The mounting plate4766 defines a hole in the free end of the plate. The upper cylindermount assembly 4764 is fixed to the decklid lift arm 4702 such that themount plate 4766 extends downwardly, and the axis of the hole ispositioned perpendicularly to the parallel members 4710 of the decklidlift arm 4702.

The decklid lift actuator 4700 further comprises a lower cylindersupport 4768. Specifically, the cylinder support 4768 comprises twoplates 4770 having a plurality of holes adapted for mounting on eitherthe support assembly 160 of the rearward frame 104 or on the supportassembly 126 of the forward frame 102. The holes of the plate 4770 arespaced wider than the width of, and substantially collinear with, thestiffener member 162 or 128 of the rearward 104 or forward 102 frame,respectively. The two plates 4770 are spaced laterally apart such thattheir surfaces are substantially parallel with yet separated slightlygreater than the width of the rectangular tubes 160 and 162. The plates4770 are fixed to one end of a rectangular steel tube 4772, preferablyby welding. The tube 4772 extends parallel therefrom, with the lowersurface of the rectangular tube 4772 offset sufficiently in the upwardvertical direction from the lower edge of the plates 4770 to accommodatean unattached plate 4774 and mechanical fasteners.

A cylinder post 4776, similar to the shock mount post 4736 is provided.As best viewed in FIG. 67, the cylinder post 4776 comprises a plate4778, having a plurality of holes, attached, preferably by welding, to acircular tube 4780 which is preferably stainless steel extendingperpendicularly therefrom. Preferably, four stiffener members 4782 areattached by welding between the plate 4778 and the tube 4780 such thatthey are substantially evenly distributed around the circumference ofthe tube 4780. The plurality of holes in plate 4778 define the cornersof a rectangle with at least one dimension wider than the transversewidth of the rectangular tube 4772. The unattached plate 4774 has aplurality of holes arranged identically to the holes in plate 4778 suchthat mechanical fasteners may be passed through the aligned holes ofplates 4774 and 4778 to fasten the cylinder post 4776 to the lowercylinder support 4768. The plate 4774 and cylinder post 4776 are fixedto the frame such that the tube 4780 extends upwardly from the cylindersupport 4768 substantially perpendicularly to the top surface of therectangular tube 4772.

A lower cylinder mount comprising a cylindrical bracket 4783,constructed and arranged as described above, is configured to clamp tothe steel tube 4780 of the cylinder post 4776. A plate 4784 is fixed,preferably by welding, to a side of the cylindrical bracket 4783 suchthat the plate 4784 extends perpendicularly to the bore axis of thecylindrical bracket 4783. A stiffening member 4786 is attached,preferably by welding, between the cylindrical bracket 4783 and theplate 4784. The plate 4784 defines a hole at the free end for attachingthe driver 4708.

A slam mechanism 4704 for closing the decklid is disposed on theintermediate segment 4712 of the decklid lift arm 4702 and is adapted toclose the decklid when the decklid lift arm 4702 is rotated in a closingdirection. A lift hand assembly 4706 is also disposed on theintermediate member 4712 of the decklid lift arm 4702 and is adapted tolift the decklid when the decklid lift arm 4702 is rotated in an openingdirection. More particularly, as shown in FIG. 69, the slam mechanismcomprises a roller 4788 rotatably mounted at an end of one arm of a bellcrank 4790. Any pliable roller 4788 suitable for contacting a decklid ofa vehicle under test without imparting damage to the decklid may beused. A FAIRLANE # DR-754-20 or equivalent is suitable for thisapplication. The bell crank 4790 having two arms angularly spaced ispivotally mounted to a bearing assembly 4792 at a point of intersectionbetween the two arms of the bell crank 4790. A suitable bearing assembly4792 is a TORRINGTON # KP-6 or equivalent. A cylindrical bracket 4793,as described above, is fixed to the bearing assembly 4792 such that theaxis of the bore of the bracket 4793 is parallel to the axis of rotationof the bell crank 4790. A mounting plate 4794 is fixed to thecylindrical bracket 4793. A driver 4796 having an extensible piston orscrew 4798, preferably an air cylinder, is mounted to the mounting plate4794 such that the extensible piston 4798 is substantially parallel withthe mounting plate 4794 and extended towards the second arm of the bellcrank 4790. The piston 4798 of the air cylinder 4796 is pivotallymounted to the end of the second arm of the bell crank 4790.

The slam mechanism 4704 is mounted to the decklid lift arm 4702 suchthat upon activation of the air cylinder 4796 the bell crank 4790 isrotated towards the decklid and the roller 4788 engages a top surface ofthe decklid.

The lift hand assembly 4706 comprises a pair of cylindrical brackets4797, as described above, aligned coaxially and fixed, preferably bywelding, to a mount plate 4800. The mount plate 4800 is fixed to asupport plate 4802. A pair of linear bearings 4804 having shaftsslidably mounted therein are disposed on the support plate 4802 suchthat the shafts are positioned parallel and spaced laterally from eachother. A conventional coupler 4806 is mounted to the shafts such thatthe coupler 4806 is movable fore and aft as the shafts slide within thelinear bearings 4804. A driver 4808 having an extensible piston,preferably an air cylinder, is mounted parallel and between the shaftsof the linear bearings 4804 such that the piston of the cylinder 4808extends parallel in the same direction as the shafts. The cylinder 4808is mounted to a cylinder mount 4810 fixed to the support shaft. The endof the extensible piston is fixed to the coupler 4806. A lift hand 4812having a substantially L-shaped configuration providing a substantiallyhorizontal surface 4814 parallel with the mount 4800 and support 4802plates is mounted to the opposite side of the coupler 4806. A bumper4816 is fixed to the surface of the lift plate 4814. Upon activation ofthe cylinder 4808, the lift plate 4814 extends or retracts as required.A suitable cylinder 4808 is provided by SMC # NCQ2B40-50. The lift handassembly 4706 is fixed to a lift hand extension arm 4818 which is fixedto the decklid lift arm 4702 such that the lift plate 4814 can extendtowards and engage the decklid under test.

The lift hand extension assembly is comprised of an extension arm 4818,a cylindrical bracket 4819, and a rod 4820. The cylindrical bracket 4819is attached, preferably by welding, in abutting relation to the upperrearward surface of the extension arm 4818 such that the bore axis ofthe bracket 4819 is substantially perpendicular to the long axis of theextension arm 4818. The rod 4820 is attached, preferably by welding, inabutting relation to the lower forward surface of the extension arm 4818such that the long axis of the rod 4820 is substantially perpendicularto the long axis of the extension arm 4818. The extension arm assemblyis attached to the intermediate member 4712 of the decklid lift arm 4702by the cylindrical bracket 4819. The lift hand assembly 4706 is attachedto the lift hand extension assembly by clamping the two lift handcylindrical brackets 4797 onto the rod 4820.

The bumper 4744 is fixed to the bumper mount 4740 and extends verticallyand upwardly to engage the decklid lift arm 4702 in a fully closedposition. A suitable bumper 4744 is a McMASTER-CARR # 9732K15 orequivalent. The damper 4742 is mounted to the shock mount 4738 andextends vertically and upwardly to engage the decklid lift arm 4702 in afully closed position. A suitable damper 4742 is the ENIDINE 1.0B-04 orequivalent. Preferably, an electric cylinder 4708 having an extensiblepiston is mounted pivotally to the upper cylinder mount 4764 at the endof the piston and is mounted pivotally at the opposed end of thecylinder 4708 to the lower cylinder mount 4822. A suitable cylinder 4708is the TH4104B-18-MP2-MT1 or equivalent.

An electric cylinder 4708 is preferred over other drivers to properlysimulate human closure of decklids. This configuration is particularlynecessary when the vehicle under test is cycled at extreme temperatures.While air cylinders may be used, they are subject to varied outputs asthe ambient temperature changes. To ensure proper simulation of thevelocity profile of a decklid being closed by a human, an electricactuator--significantly less affected by temperature extremes--ispreferred.

Additionally, while the control system should slow the decklid lift arm4702 down before the electric cylinder 4708 bottoms, the bumper 4744 anddamper 4742 provides additional protection to the actuator. Thus, thebumper 4744 and damper 4742 should be positioned relative to the decklidlift arm 4702 such that the decklid lift arm 4702 engages the bumper4744 after a stroke of the actuator sufficient to rotate the arm 4702 toclose the decklid has been applied, but before the electric actuator4708 bottoms. Moreover, given that the decklid actuator 4700 can be usedto slam the decklid, the damper 4742 provides a device to dissipate theenergy of the moving decklid lift arm 4702.

The decklid lift actuators are provided preferably in two sizes. A smalldecklid lift actuator is adapted for use with decklids of compactvehicles. A large decklid actuator is adapted for use with largervehicles. Both decklid lift actuators are constructed and arrangedidentically except that the relative dimensions are increased for thelarger actuator and the driver is sized for the larger loads expectedfrom larger vehicle decklids.

HANDLE AND CHECK LOAD ACTUATORS

HANDLE ACTUATORS

Outside handle actuator

As shown in FIG. 71, an outside door handle actuator 1500 is provided.The outside door handle actuator 1500 comprises preferably an aircylinder 1502 having an extensible piston 1504. Other linear actuators,however, may be incorporated including electric actuators and hydrauliccylinders. A cylindrical bracket 1506 is attached to each of the opposedends of the air cylinder 1502. Specifically, as can be seen in FIG. 75,the cylindrical bracket 1506 comprises a flat plate defining a pair ofholes spaced laterally from a center of the plate through whichmechanical fasteners pass to attach the plate to the air cylinder 1502.The cylindrical bracket 1506 further comprises two mating semi-circularmembers that, upon assembly, define a bore therethrough fixed,preferably by welding, to the plate. The two semi-circular members areadapted to be connected to an outside door arm 1508 by separating thehalves, positioning the halves about the outside door arm 1508, andclamping the halves to the outside door arm 1508 by any suitable means.Specifically, the semi-circular members incorporates screws that passthrough one semi-circular member and tighten upon threads tapped intothe opposing semi-circular member. As can be seen in FIG. 76, thesemi-circular members are fixed to the plates such that the bores areoriented substantially parallel to the air cylinder 1502. The aircylinder 1502 is positioned preferably on the vertical member of theoutside door arm 1508 below the level of the door handle.

An idler sprocket assembly 1510 is fixed on the vertical member of theoutside door arm 1508 above the air cylinder 1502. The idler sprocketassembly 1510 comprises an idler sprocket 1512, preferably 1/4 pitch,rotatably mounted to a plate 1514. As can be seen in FIG. 76, acylindrical bracket 1516 is fixed, preferably by welding, to the opposedsurface of the plate 1514. The cylindrical bracket 1516 comprises twomating semi-circular members that, upon assembly, define a boretherethrough. As best viewed in FIG. 71, the two semi-circular membersare adapted to be connected to the vertical member of an outside doorarm 1508 by separating the halves, positioning the halves about theoutside door arm 1508, and clamping the halves to the outside door arm1508 by any suitable means. Specifically, the semi-circular membersincorporates screws that pass through one semi-circular member andtighten upon threads tapped into the opposing semi-circular member. Asshown in FIG. 73, the semi-circular members are fixed to the plate 1514such that the bore is oriented substantially parallel to the aircylinder 1502. Moreover, the idler sprocket assembly 1510 is fixed tothe door arm 1508 such that the axis of the idler sprocket 1512 issubstantially parallel with the door under test. As configured, theidler sprocket 1512 is fixed to the plate 1514 and thereby to the doorarm 1508, subject to the relative positioning of the idler sprocket 1512to the door under test as described above, such that the leading toothedsurface of the idler sprocket 1512 is coextensive with a center line ofthe air cylinder 1502.

The air cylinder piston 1504 is attached to a chain and spring assembly1518, as described more fully below. The chain 1520 is fixed at one endto the spring assembly 1522 of the air cylinder 1502 and is attached atthe other end to an outside handle base 1524. More particularly, thechain 1520 extends from the air cylinder spring assembly 1522 along thecenter line of the air cylinder 1502 to the leading toothed surface ofthe idler sprocket 1512 and thereafter extends downwardly to the outsidehandle base 1524. The outside handle base 1524 is fixed to the doorhandle.

The outside handle base 1524 comprises a C-shaped bracket 1526,preferably constructed from aluminum, and a rod and spacer assembly1528, preferably constructed from acetal resin or its equivalentincluding, for example DELRIN, mounted within the C-shaped bracket 1526.More particularly, as can be seen in FIG. 74, the C-shaped bracket 1526includes a perpendicular portion disposed between two parallel portions.The C-shaped bracket 1526 includes penhole through the perpendicularportion through which a mechanical fastener passes to attach the chain1520 to the C-shaped bracket 1526. Each of the parallel portions definea hole therethrough; the hole through the lower parallel portion,however, is aligned perpendicularly to the other holes. The rod 1530 hasa tapped bore within a substantial portion of its length and has adiameter larger than the thickness of the lower parallel portion. Therod 1530 is fixed to the lower parallel portion by a mechanical fastenerand extends perpendicularly to the other holes. As can be seen in FIG.75, a spacer 1532 is positioned between the parallel portion coaxiallywith the hole of the upper parallel portion. The spacer 1532 is biasedtowards the rod 1530 by a bolt threaded in the hole of the upperparallel portion. As assembled to a handle of a door under test, thespacer 1532 is biased towards the outside surface of a horizontallyhinged handle thereby clamping the handle between the spacer 1532 andthe rod 1530.

The spring assembly 1522 comprises a conventional extension spring 1534that allows relative movement between the air cylinder piston 1504 andthe chain 1520. A suitable extension spring 1534 is a McMaster-Carr#9630K1 or equivalent. Generally, the extension spring 1534 must have aspring constant that will produce a force sufficient to open the outsidedoor handle of the vehicle under test. The spring 1534 is disposedcoaxially and coextensively with the piston 1504 of the air cylinder1502. One end of the extension spring 1534 is connected to the chain1520 while the other end abuts the air cylinder 1502. As configured,upon engagement of the air cylinder 1502 in a retracting direction, theextension spring 1534 is biased allowing the air cylinder piston 1504 tomove relatively to the chain 1534. During the stroke of the piston 1504,the extension spring 1534 is also biased by a door handle load on thechain 1520 until the point where the spring force overcomes the doorhandle load. At such a point, continued retraction of the air cylinderpiston 1504 pulls the chain 1520 and outside handle base 1524.

As configured, the extension spring assembly 1522 provides relativemovement between the air cylinder piston 1504 and the chain 1520. Thisrelative movement assures that constant tension is provided on the chain1520 and takes up chain slack. Indeed, once the latch of the door undertest is released, the door seal biases the door in an opening direction.During this time, the door may lead the chain 1520 thereby impartingslack to the chain 1520. Without the extension spring 1534, the actuator1500 would open the handle of the door under test, allow the handle toclose as slack formed in the chain 1520, and then jerk the handle openagain as the chain 1520 and air cylinder piston 1504 caught up. However,the extension spring 1534 biases the chain 1520 to take up the slacksuch that the chain 1520 remains in tension. Moreover, thechain-tensioning capability of the extension spring 1534 preventsjerk-type loading on the door handle which would otherwise occur afterthe chain 1520 catches up with the leading door. In that regard,therefore, the outside door handle actuator 1500 is able to simulate theconstant and uniform pull of a human opening the door handle.

The outside door handle actuator 1500 is provided preferably in twoconfigurations. In the first configuration, the air cylinder 1502 issized for smaller handle loads and smaller doors. As such, the firstconfiguration is adapted typically for use with the small main frame100. In the second configuration, the air cylinder 1502 is sized forlarger handle loads and larger doors. As such, the second configurationis adapted typically for use with the medium mainframe 300 and largemainframe 500 since those frames usually are used with larger vehicles.

Check load actuator

As shown in FIGS. 76 and 77, the check load fixture 600 loads the doorunder test beyond the full-open position. In that regard, the check loadfixture 600 simulates an overload condition on the door that occurs, forexample, when wind catches the door and pushes the door against the fullopen check. Additionally, given the modular configuration, the checkload fixture 600 can also load the door under test in a substantiallyvertical direction.

Generally, the check load fixture 600, shown in FIGS. 76 and 77,comprises a pair of air cylinders 601, 602 disposed substantiallyperpendicular to each other thereby providing longitudinal and lateralmovement of the fixture. While air fixtures are incorporated in thisembodiment, one skilled in the art will recognize readily that anysuitable actuator, including hydraulic or electric actuators, may beincorporated. The check load fixture 600 further comprises a cylindricalbracket 626 for securing the check load fixture 600 to an outside doorarm.

Specifically, the check load fixture 600 comprises a load air cylindermount 603, preferably an aluminum plate, having threaded borestherethrough spaced at uniform intervals providing the attachment pointsfor a load air cylinder 601. A linear bearing 604 is disposed on theload air cylinder mount 603, and a shaft carriage 605 is mountedslidably thereto. A load shaft 606 is fixed perpendicularly to theslidable shaft carriage 605 with a clamp 607 and extends laterallytherefrom. The load shaft 606 provides the bearing surface which engagesand loads the door under test. Preferably, a flat bearing surface isdisposed on the free end of the load shaft 606 to provide a bettercontact to the door under test.

The shaft carriage 605 includes a flange 608 extending perpendicularlyto the longitudinal direction of the load air cylinder mount 603 anddiagonally opposite from the load shaft 606. The load air cylinder 601is fixed to the load air cylinder mount 603 and is spaced laterally fromand substantially parallel to the linear bearing 604 but alignedlongitudinally with the flange 608 of the shaft carriage 605. A piston609 of the load air cylinder 601 having a load cell 610 attached at itsfree end is fixed with a clamp 611 to the flange 608 of the shaftcarriage 605. Activation of the air cylinder 601 displaces the shaftcarriage 605 in a longitudinal direction. The load cell 610 provides afeedback signal proportional to the load applied and is incorporatedinto the control apparatus, described below.

Disposed below the load air cylinder mount 603, a lateral air cylinderassembly 612 is provided. One skilled in the art will recognize that thelateral air cylinder assembly 612 can be disposed effectively above theload air cylinder mount 603 as well. The lateral air cylinder assembly612 comprises a lateral air cylinder mount 613 having a plurality ofholes at each of opposing lateral sides. As shown in FIG. 78, thelateral air cylinder mount 613 also defines a pair of slots 614providing convenient passages for air hoses. Clamping blocks 615, 616are attached to each of the opposing sides of the lateral air cylindermount 613 at the provided holes. Mechanical fasteners passing throughthe holes secure the clamping blocks 615, 616 to the lateral aircylinder mount 613. The clamping block 615 shown in FIG. 79 defines acentrally positioned hole 617 through which a piston 618 of a lateralair cylinder 602 passes. The clamping block 616 shown in FIG. 80provides a centrally positioned mount 619 for the lateral air cylinder602. Both of the clamping blocks 615, 616 define two holes 620 spacedlaterally from the center providing attachment points for shafts 621slidably mounted in ball bushing bearings 622. In the presentembodiment, the laterally spaced holes 620 include expansion slits 623extending from the holes 620. Once a shaft 621 is positioned within alateral hole 620, the surrounding mount 615, 616 can be clamped onto theshaft 621 by mechanical fasteners.

The ball bushing bearings 622 are mounted to an opposed surface of theload air cylinder mount 603, and, thereafter, the shafts 621 areinserted into the bearings 622 and fixed to the clamps 615, 616. In thisconfiguration, the lateral air cylinder mount 613 can slide relative tothe load air cylinder mount 603. The lateral air cylinder 602 is fixedto the clamp 616 and lateral air cylinder mount 613 such that the piston618 is extensible through the hole 617 of the clamp 615. The free end ofthe piston 618 is connected to an L-shaped bracket 624 with a clamp 625such the bracket 624 extend upwardly to the load air cylinder mount 603.The L-shaped bracket 624 is fixed to the load air cylinder mount 603such that, upon activation of the lateral air cylinder 602, the load aircylinder mount slides 603 laterally relative to the lateral air cylindermount 613.

Finally, the check load fixture 600 comprises a cylindrical bracket 626.The cylindrical bracket 626 comprises two mating semi-circular membersthat, upon assembly, define a bore therethrough. The two semi-circularmembers are adapted to be connected to the vertical arm of a pivot armof an outside door actuator by separating the halves, positioning thehalves about the vertical arm of the pivot arm, and clamping the halvesto the pivot arm by any suitable means. Specifically, the semi-circularmembers of the upper pivot bracket incorporates screws that pass throughone semi-circular member and tighten upon threads tapped into theopposing semi-circular member. The cylindrical bracket 626 is fixed,preferably by welding, to the lateral air cylinder mount 613 such thatbore of the bracket 626 is substantially perpendicular to the lateralair cylinder mount 613. Preferably, a brace is fixed between thecylindrical bracket 626 and the lateral air cylinder mount 613.

The check load fixture should be provided preferably in two sizes. Ashort check load fixture should be adapted for relatively shorteractuator strokes, while a long check load fixture should be adapted forrelatively longer actuator strokes. Each of the check load fixtures areconstructed and arranged identically except for their relativedimensions and the stroke of the air cylinders incorporated therein.

SYSTEM DESCRIPTION

The CST apparatus operates as a system to simultaneously cycle allvehicle closures (1) without loading the vehicle under test withextraneous mass or force in a manner that simulates human use and (2) ona portable platform that allows the vehicle under test to be transportedto different test locations without the need for reconfiguration. Theconfiguration and operation of the frames and actuation modules aredescribed above. As shown in FIG. 81, the actuation modules and framesare only one part of the total CST system and are representedcollectively by the TEST FIXTURE block.

Central to the control and operation of the CST system is a programmablelogic controller (PLC) represented by a block of the same name. The PLCis a matter of design choice and can be either a computer, for example aPC or workstation, or a dedicated controller. Any controller havingsufficient outputs to control the expected number of relays and airvalve banks is acceptable. A PLC program, adapted, of course, for use onthe selected controller, provides the control algorithms, discussedbelow, for operation of the CST system. Preferably, the PLC shouldinclude an OPERATOR GRAPHICAL INTERFACE (OGI) that provides the userwith, at least, the current number of door cycles and the total numberof door cycles. Such a graphical interface is shown in FIG. 82. As shownin FIG. 83, the OGI should provide preferably a screen indicating thestatus of PLC inputs and outputs. Such inputs and outputs would includedoor open/closed status, door actuator extended/retracted status, andhandle and/or lock status (if such actuators are used).

Again as shown in FIG. 81, the PLC output controls a RELAY BANK and anAIR VALVE BANK. The relay bank contains a plurality of relays, thenumber of which is determined by the number of modules, for activatingor energizing the actuation modules. The relay bank is powered by a DCPOWER SUPPLY. As described below the relay bank is connected to a WIRINGJUNCTION BOX. Similarly, the air valve bank contains a plurality of airvalves, the number of which is determined by the number of air cylindersused, for operating the air cylinders. The air valve bank is connectedto the test fixture.

Since the object of the CST system is to simulate human closure ofvehicle doors, as described above, electric actuators are most suitablyincorporated into the CST system because they provide the best controlover velocity profiles of door closure. Consequently, the PLC isinterfaced to an ELECTRIC ACTUATOR CONTROLLER. The electric actuatorcontroller is connected to the wiring junction box.

Any electric actuator that can output a velocity profile necessary tocycle a vehicle door in a manner that simulates human closure of a dooris acceptable. The electric actuator should be able to accelerate a doorunder test to higher velocity levels to slam the door as well as providesubstantially constant velocity closure of doors. Industrial DevicesCorporation H3301 series electric actuators are suitable for thisapplication. Such actuators incorporate travel limit switches to detectthe linear or rotary position of the actuator. The electric actuatorcontroller provides the interface between the PLC and the electricactuator for the transfer of control and feedback signals.

The wiring junction box and the air valve bank are provide with quickdisconnects of any suitable make or design that allow easy disconnectionof the test fixture from and reconnection to the remaining CST system.As configured, the test fixture can be disconnected from the PLC andtransported to a different test site on the moving gears and thereafterbe reconnected at the new site, for example, a temperature chamber.

FIGS. 84 through 89 show in flow chart form the algorithms used by thePLC program to control the test fixture. As shown in FIG. 84, followingsystem power up and initial test set-up, the PLC program provides theoption of cycling the test fixture in automatic or manual mode. Once thePLC receives confirmation of automatic cycling, the automatic test cyclebegins. Initially, the PLC program determines whether the door undertest will be cycled form the inside or outside of the vehicle. FIG. 84shows the program control for an outside door actuator, while FIG. 85shows the program control for an inside door actuator. Generally in bothcases, the door window is cycled (if such an actuator is beingutilized), the door lock is then cycled (again, if such an actuator isutilized), the door latch is released by activation of either an insidehandle actuator or an outside handle actuator, as applicable, the dooris pulled or pushed open, as applicable, and finally, the door is pulledor pushed closed, as applicable. Once the PLC receives confirmation thatthe door is closed, the program increments a cycle count. In the finalstep, the PLC program checks the cycle count with a pre-programmed fullcount and either stops the cycling if the cycle count equals the fullcount or continues cycling if the cycle count is less than the fullcount.

FIGS. 84 and 85 only show the flow control for a single door. Oneskilled in the art will appreciate that the PLC can control multipledoors simultaneously.

FIG. 86 shows the program flow for a window actuator. The PLC programchecks the cycle count and verifies that the door is closed prior tocycling the window under test. Thereafter, the window position isdetermined so that a full cycle of the window can be performed. Afterthe window is cycled, the cycle count is incremented. The PLC programexits from the window cycle when the cycle count reaches apre-programmed level.

FIG. 87 shows the program flow for a lock actuator. As with the windowcycle program, the PLC program checks the cycle count and verifies thatthe door is closed prior to cycling the door lock under test. The PLCprogram verifies the lock type--key, power, or night or plunger typelock--and thereafter cycles the lock. Program control then passes toeither an outside or inside handle control as applicable.

FIGS. 88 and 89 show the program flow control for an outside and insidehandle actuator, respectively.

One skilled in the art will recognize readily that the sequence ofprogram flow control can proceed in orders other than that describedabove (except, of course, a door latch of a latched door must bereleased before the door is opened). Additionally, windows and locks canbe cycled in batch prior to cycling the door, or they can be cycledincrementally each time the door is cycled.

What is claimed is:
 1. In a vehicle closure testing apparatus foropening and closing a particular vehicle door of a particular vehicleunder test, the particular vehicle door having an exterior surface and aparticular axis of rotation, said apparatus including a supportingstructure constructed and arranged to be positioned outside of theparticular vehicle under test such that said supporting structure is ina spaced relationship to the exterior surface of the particular vehicledoor and is disposed in an operative position relative to the particularvehicle under test during a testing of the particular vehicle door, anda door moving mechanism movably disposed on said supporting structure ata position on said supporting structure that enables said door movingmechanism to engage the exterior surface of the particular vehicle doorhaving the particular axis of rotation when said supporting structure isin said operative position, said door moving mechanism being constructedand arranged to move in a first direction and in a second directioncounter to said first direction such that said door moving mechanism canengage the exterior surface of the particular vehicle door and move theparticular vehicle door in an opening direction and a closing direction,the improvement which comprises:an assembly disposed on said supportingstructure capable of being selectably configured to position said doormoving mechanism in functional positions relative to exterior surfacesof a variety of vehicle doors having different axes of rotation so thatsaid door moving mechanism can engage and move any of the variety ofvehicle doors, said door moving mechanism being movably mounted on saidassembly, said assembly being constructed and arranged to enable saiddoor moving mechanism to be movably positioned into a functionalposition relative to a specific exterior surface of a specific one ofthe variety of vehicle doors having a specific axis of rotation suchthat when the specific vehicle door is under test, said door movingmechanism pivots about one of an axis parallel to the specific vehicledoor axis and an axis aligned and coextensive with the specific vehicledoor axis, and so that said assembly can be selectably re-configured tore-position said door moving mechanism in a similar functional positionrelative to a different exterior surface of a different vehicle doorhaving a different axis of rotation such that when the different vehicledoor is under test, said door moving mechanism pivots about one of anaxis parallel to the different vehicle door axis and an axis aligned andcoextensive with the different vehicle door axis.
 2. A vehicle closuretesting apparatus according to claim 1, wherein said assembly isconstructed and arranged to enable a member of said door movingmechanism to be laterally movable relative to any of the variety ofvehicle doors having a variety of lengths such that said assembly can beconfigured to selectably position said member anywhere along a length ofthe specific exterior surface of the specific vehicle door and such thatsaid assembly can be re-configured to selectably re-position said memberanywhere along a length of the different exterior surface of thedifferent vehicle door.
 3. In a vehicle closure testing apparatus foropening and closing a particular vehicle door of a particular vehicleunder test, the particular vehicle door having an interior surface and aparticular axis of rotation, said apparatus including a supportingstructure constructed and arranged to be positioned inside of theparticular vehicle under test such that said supporting structure is ina spaced relationship to the interior surface of the particular vehicledoor and is disposed in an operative position relative to the particularvehicle under test during a testing of the particular vehicle door, anda door moving mechanism movably disposed on said supporting structure ata position on said supporting structure that enables said door movingmechanism to engage the interior surface of the particular vehicle doorhaving the particular axis of rotation when said supporting structure isin said operative position, said door moving mechanism being constructedand arranged to move in a first direction and in a second directioncounter to said first direction such that said door moving mechanism canengage the interior surface of the particular vehicle door and move theparticular vehicle door in an opening direction and a closing direction,the improvement which comprises:an assembly disposed on said supportingstructure capable of being selectably configured to position said doormoving mechanism in functional positions relative to interior surfacesof a variety of vehicle doors having different axes of rotation so thatsaid door moving mechanism can engage and move any of the variety ofvehicle doors, said door moving mechanism being movably mounted on saidassembly, said assembly being constructed and arranged to enable saiddoor moving mechanism to be movably positioned into a functionalposition relative to a specific interior surface of a specific one ofthe variety of vehicle doors having a specific axis of rotation suchthat when the specific vehicle door is under test, said door movingmechanism pivots about one of an axis parallel to the specific vehicledoor axis and an axis aligned and coextensive with the specific vehicledoor axis, and so that said assembly can be selectably re-configured tore-position said door moving mechanism in a similar functional positionrelative to a different interior surface of a different vehicle doorhaving a different axis of rotation such that when the different vehicledoor is under test, said door moving mechanism pivots about one of anaxis parallel to the different vehicle door axis and an axis aligned andcoextensive with the different vehicle door axis.
 4. In a vehicleclosure testing apparatus for opening and closing a particular vehicledoor of a particular vehicle under test, the particular vehicle doorhaving a particular axis of rotation, an exterior surface and aninterior surface, said apparatus including an outside supportingstructure constructed and arranged to be positioned outside of theparticular vehicle under test such that said outside supportingstructure is in a spaced relationship to the exterior surface of theparticular vehicle door and is disposed in an outside operative positionrelative to the particular vehicle under test during a testing of theparticular vehicle door, an inside supporting structure constructed andarranged to be positioned inside of the particular vehicle under testsuch that said inside supporting structure is in a spaced relationshipto the interior surface of the particular vehicle door and is disposedin an inside operative position relative to the particular vehicle undertest during a testing of the particular vehicle door, an outside doormoving mechanism movably disposed on said outside supporting structureat a position on said outside supporting structure that enables saidoutside door moving mechanism to engage the exterior surface of theparticular vehicle door having the particular axis of rotation when saidoutside supporting structure is in said outside operative position, saidoutside door moving mechanism being constructed and arranged to move ina first direction and in a second direction counter to said firstdirection such that said outside door moving mechanism can engage theexterior surface of the particular vehicle door and move the particularvehicle door in one of an opening direction and a closing direction, andan inside door moving mechanism movably disposed on said insidesupporting structure at a position on said inside supporting structurethat enables said inside door moving mechanism to engage the interiorsurface of the particular vehicle door having the particular axis ofrotation when said inside supporting structure is in said insideoperative position, said inside door moving mechanism being constructedand arranged to move in a third direction and in a fourth directioncounter to said third direction such that said inside door movingmechanism can engage the interior surface of the particular vehicle doorand move the particular vehicle door in the other of the openingdirection and the closing direction, the improvement which comprises:anoutside assembly disposed on said outside supporting structure capableof being selectably configured to position said outside door movingmechanism in functional positions relative to exterior surfaces of avariety of vehicle doors having various axes of rotation so that saidoutside door moving mechanism can engage and move any of the variety ofvehicle doors, said outside door moving mechanism being movably mountedon said outside assembly, said outside assembly being constructed andarranged to enable said outside door moving mechanism to be movablypositioned into an outside functional position relative to a specificexterior surface of a specific vehicle door of the variety of vehicledoors, said specific vehicle door having a specific axis of rotationsuch that when the specific vehicle door is under test, said outsidedoor moving mechanism pivots about one of an axis parallel to thespecific vehicle door axis and an axis aligned and coextensive with thespecific vehicle door axis, and so that said outside assembly can beselectably re-configured to re-position said outside door movingmechanism in a similar outside functional position relative to adifferent exterior surface of a different vehicle door having adifferent axis of rotation such that when the different vehicle door isunder test, said outside door moving mechanism pivots about one of anaxis parallel to the different vehicle door axis and an axis aligned andcoextensive with the different vehicle door axis; and an inside assemblydisposed on said inside supporting structure capable of being selectablyconfigured to position said inside door moving mechanism in functionalpositions relative to interior surfaces of the variety of vehicle doorshaving various axes of rotation so that said inside door movingmechanism can engage and move any of the variety of vehicle doors, saidinside door moving mechanism being movably mounted on said insideassembly, said inside assembly being constructed and arranged to enablesaid inside door moving mechanism to be movably positioned into aninside functional position relative to a specific interior surface ofthe specific vehicle door of the variety of vehicle doors having thespecific axis of rotation such that when the specific vehicle door isunder test, said inside door moving mechanism pivots about one of anaxis parallel to the specific vehicle door axis and an axis aligned andcoextensive with the specific vehicle door axis, and so that said insideassembly can be selectably re-configured to re-position said inside doormoving mechanism in a similar inside functional position relative to adifferent interior surface of the different vehicle door having thedifferent axis of rotation such that when the different vehicle door isunder test, said inside door moving mechanism pivots about one of anaxis parallel to the different vehicle door axis and an axis aligned andcoextensive with the different vehicle door axis.
 5. A vehicle closuretesting apparatus according to claim 4, wherein said outside assembly isconstructed and arranged to enable a member of said outside door movingmechanism to be laterally movable relative to any of the variety ofvehicle doors having a variety of lengths such that said outsideassembly can be configured to selectably position said member anywherealong a length of the specific exterior surface of the specific vehicledoor and such that said outside assembly can be re-configured toselectably re-position said member anywhere along a length of thedifferent exterior surface of the different vehicle door.
 6. In avehicle closure testing apparatus for opening and closing a particularvehicle door of a particular, fully-operational vehicle under test, theparticular vehicle door having an exterior surface and a particular axisof rotation, said apparatus including a supporting structure constructedand arranged to allow the particular, fully-operational vehicle undertest to be driven onto said supporting structure and to support theparticular, fully-operational vehicle under test including the vehicle'swheels and suspension, said supporting structure being constructed andarranged to position said supporting structure outside of theparticular, fully operational vehicle under test such that saidsupporting structure is in a spaced relationship to the exterior surfaceof the particular vehicle door and is disposed in an operative positionrelative to the particular, fully-operational vehicle under test duringa testing of the particular vehicle door, a door moving mechanismmovably disposed on said supporting structure at a position on saidsupporting structure that enables said door moving mechanism to engagean area of contact on the exterior surface of the particular vehicledoor having the particular axis of rotation when said supportingstructure is in said operative position, said door moving mechanismbeing constructed and arranged to move in a first direction and in asecond direction counter to said first direction such that said doormoving mechanism can engage the area of contact on the exterior surfaceof the particular vehicle door and move the particular vehicle door inan opening direction and a closing direction such that the area ofcontact remains fixed while said door moving mechanism moves theparticular vehicle door, an electric actuator operatively associatedwith said door moving mechanism constructed and arranged to activatesaid door moving mechanism and cause said door moving mechanism toengage and move the particular vehicle door in the opening direction andthe closing direction, and an electric actuator controller communicatingwith said electric actuator so as to transfer control signals to saidelectric actuator and to receive feedback signals indicative of doormovements during the movement of said door moving mechanism such thatsaid electric actuator controller can control said electric actuator toobtain a desired velocity profile in the movement of the particularvehicle door by said door moving mechanism, the improvement whichcomprises:an assembly disposed on said supporting structure capable ofbeing selectably configured to position said door moving mechanism infunctional positions relative to exterior surfaces of a variety ofvehicle doors having different axes of rotation so that said door movingmechanism can engage and move any of the variety of vehicle doors, saiddoor moving mechanism being movably mounted on said assembly, saidassembly being constructed and arranged to enable said door movingmechanism to be movably positioned into a functional position relativeto a specific exterior surface of a specific one of the variety ofvehicle doors having a specific axis of rotation such that when thespecific vehicle door is under test, said door moving mechanism pivotsabout one of an axis parallel to the specific vehicle door axis and anaxis aligned and coextensive with the specific vehicle door axis, and sothat said assembly can be selectably re-configured to re-position saiddoor moving mechanism in a similar functional position relative to adifferent exterior surface of a different vehicle door having adifferent axis of rotation such that when the different vehicle door isunder test, said door moving mechanism pivots about one of an axisparallel to the different vehicle door axis and an axis aligned andcoextensive with the different vehicle door axis.
 7. A vehicle closuretesting apparatus according to claim 6, wherein said assembly isconstructed and arranged to enable a member of said door movingmechanism to be laterally movable relative to any of the variety ofvehicle doors having a variety of lengths such that said assembly can beconfigured to selectably position said member anywhere along a length ofthe specific exterior surface of the specific vehicle door and such thatsaid assembly can be re-configured to selectably re-position said memberanywhere along a length of the different exterior surface of thedifferent vehicle door.
 8. In a vehicle closure testing apparatus foropening and closing a particular vehicle door of a particular,fully-operational vehicle under test including the vehicle's wheels andsuspension, the particular vehicle door having an interior surface and aparticular axis of rotation, said apparatus including a supportingstructure constructed and arranged to be disposed within an interior ofthe particular, fully-operational vehicle under test, said supportingstructure being constructed and arranged to be positioned inside of theparticular, fully-operational vehicle under test such that saidsupporting structure is in a spaced relationship to the interior surfaceof the particular vehicle door and is disposed in an operative positionrelative to the particular vehicle under test during a testing of theparticular vehicle door, a door moving mechanism movably disposed onsaid supporting structure at a position on said supporting structurethat enables said door moving mechanism to engage an area of contact onthe interior surface of the particular vehicle door having theparticular axis of rotation when said supporting structure is in saidoperative position, said door moving mechanism being constructed andarranged to move in a first direction and in a second direction counterto said first direction such that said door moving mechanism can engagearea of contact on the interior surface of the particular vehicle doorand move the particular vehicle door in an opening direction and aclosing direction such that the area of contact remains fixed while saiddoor moving mechanism moves the particular vehicle door, an electricactuator operatively associated with said door moving mechanismconstructed and arranged to activate said door moving mechanism andcause said door moving mechanism to engage and move the particularvehicle door in the opening direction and the closing direction, and anelectric actuator controller communicating with said electric actuatorso as to transfer control signals to said electric actuator and toreceive feedback signals indicative of door movements during themovement of said door moving mechanism such that said electric actuatorcontroller can control said electric actuator to obtain a desiredvelocity profile in the movement of the particular vehicle door by saiddoor moving mechanism, the improvement which comprises:an assemblydisposed on said supporting structure capable of being selectablyconfigured to position said door moving mechanism in functionalpositions relative to interior surfaces of a variety of vehicle doorshaving different axes of rotation so that said door moving mechanism canengage and move any of the variety of vehicle doors, said door movingmechanism being movably mounted on said assembly, said assembly beingconstructed and arranged to enable said door moving mechanism to bemovably positioned into a functional position relative to a specificinterior surface of a specific one of the variety of vehicle doorshaving a specific axis of rotation such that when the specific vehicledoor is under test, said door moving mechanism pivots about one of anaxis parallel to the specific vehicle door axis and an axis aligned andcoextensive with the specific vehicle door axis, and so that saidassembly can be selectably re-configured to re-position said door movingmechanism in a similar functional position relative to a differentinterior surface of a different vehicle door having a different axis ofrotation such that when the different vehicle door is under test, saiddoor moving mechanism pivots about one of an axis parallel to thedifferent vehicle door axis and an axis aligned and coextensive with thedifferent vehicle door axis.
 9. In a vehicle closure testing apparatusfor opening and closing a particular vehicle door of a particular,fully-operational vehicle under test, the particular vehicle door havinga particular axis of rotation, an exterior surface and an interiorsurface, said apparatus including an outside supporting structureconstructed and arranged to allow the particular, fully-operationalvehicle under test to be driven onto said outside supporting structureand to support the particular, fully-operational vehicle under testincluding the vehicle's wheels and suspension, said outside supportingstructure being constructed and arranged to position said outsidesupporting structure outside of the particular, fully-operationalvehicle under test such that said outside supporting structure is in aspaced relationship to the exterior surface of the particular vehicledoor and is disposed in an outside operative position relative to theparticular, fully-operational vehicle under test during a testing of theparticular vehicle door, an inside supporting structure constructed andarranged to be disposed within an interior of the particular,fully-operational vehicle under test, said inside supporting structurebeing constructed and arranged to be positioned inside of theparticular, fully-operational vehicle under test such that said insidesupporting structure is in a spaced relationship to the interior surfaceof the particular vehicle door and is disposed in an inside operativeposition relative to the particular vehicle under test during a testingof the particular vehicle door, an outside door moving mechanism movablydisposed on said outside supporting structure at a position on saidoutside supporting structure that enables said outside door movingmechanism to engage an outside area of contact on the exterior surfaceof the particular vehicle door having the particular axis of rotationwhen said outside supporting structure is in said outside operativeposition, said outside door moving mechanism being constructed andarranged to move in a first direction and in a second direction counterto said first direction such that said outside door moving mechanism canengage the outside area of contact on the exterior surface of theparticular vehicle door and move the particular vehicle door in one ofan opening direction and a closing direction such that the outside areaof contact remains fixed while said outside door moving mechanism movesthe particular vehicle door, an inside door moving mechanism movablydisposed on said inside supporting structure at a position on saidinside supporting structure that enables said inside door movingmechanism to engage an inside area of contact on the interior surfacethe interior surface of the particular vehicle door having theparticular axis of rotation when said inside supporting structure is insaid inside operative position, said inside door moving mechanism beingconstructed and arranged to move in a third direction and in a fourthdirection counter to said third direction such that said inside doormoving mechanism can engage the inside area of contact on the interiorsurface of the particular vehicle door and move the particular vehicledoor in the other of the opening direction and the closing directionsuch that the inside area of contact remains fixed while said insidedoor moving mechanism moves the particular vehicle door, an outsideelectric actuator operatively associated with said outside door movingmechanism constructed and arranged to activate said outside door movingmechanism and cause said outside door moving mechanism to engage andmove the particular vehicle door in one of the opening direction and theclosing direction, an inside electric actuator operatively associatedwith said inside door moving mechanism constructed and arranged toactivate said inside door moving mechanism to engage and move theparticular vehicle door in the other of the opening and closingdirection, an electric actuator controller communicating with saidoutside electric actuator and said inside electric actuator so as totransfer control signals to said outside electric actuator and saidinside electric actuator and to receive feedback signals indicative ofdoor movements such that said electric actuator controller can controlsaid outside electric actuator and said inside electric actuator toobtain a desired velocity profile in the movement of the particularvehicle door by said outside door moving mechanism and said inside doormoving mechanism, the improvement which comprises;an outside assemblydisposed on said outside supporting structure capable of beingselectably configured to position said outside door moving mechanism infunctional positions relative to exterior surfaces of a variety ofvehicle doors having various axes of rotation so that said outside doormoving mechanism can engage and move any of the variety of vehicledoors, said outside door moving mechanism being movably mounted on saidoutside assembly, said outside assembly being constructed and arrangedto enable said outside door moving mechanism to be movably positionedinto an outside functional position relative to a specific exteriorsurface of a specific vehicle door of the variety of vehicle doors, saidspecific vehicle door having a specific axis of rotation such that whenthe specific vehicle door is under test, said outside door movingmechanism pivots about one of an axis parallel to the specific vehicledoor axis and an axis aligned and coextensive with the specific vehicledoor axis, and so that said outside assembly can be selectablyre-configured to re-position said outside door moving mechanism in asimilar outside functional position relative to a different exteriorsurface of a different vehicle door having a different axis of rotationsuch that when the different vehicle door is under test, said outsidedoor moving mechanism pivots about one of an axis parallel to thedifferent vehicle door axis and an axis aligned and coextensive with thedifferent vehicle door axis; and an inside assembly disposed on saidinside supporting structure capable of being selectably configured toposition said inside door moving mechanism in functional positionsrelative to interior surfaces of the variety of vehicle doors havingvarious axes of rotation so that said inside door moving mechanism canengage and move any of the variety of vehicle doors, said inside doormoving mechanism being movably mounted on said inside assembly, saidinside assembly being constructed and arranged to enable said insidedoor moving mechanism to be movably positioned into an inside functionalposition relative to a specific interior surface of the specific vehicledoor of the variety of vehicle doors having the specific axis ofrotation such that when the specific vehicle door is under test, saidinside door moving mechanism pivots about one of an axis parallel to thespecific vehicle door axis and an axis aligned and coextensive with thespecific vehicle door axis, and so that said inside assembly can beselectably re-configured to re-position said inside door movingmechanism in a similar inside functional position relative to adifferent interior surface of the different vehicle door having thedifferent axis of rotation such that when the different vehicle door isunder test, said inside door moving mechanism pivots about one of anaxis parallel to the different vehicle door axis and an axis aligned andcoextensive with the different vehicle door axis.
 10. A vehicle closuretesting apparatus according to claim 9, wherein said outside assembly isconstructed and arranged to enable a member of said outside door movingmechanism to be laterally movable relative to any of the variety ofvehicle doors having a variety of lengths such that said outsideassembly can be configured to selectably position said member anywherealong a length of the specific exterior surface of the specific vehicledoor and such that said outside assembly can be re-configured toselectably re-position said member anywhere along a length of thedifferent exterior surface of the different vehicle door.